EDBCSXM064.6Rc. Ä.6Rcä. Operating Instructions ECS. ECSEMxxx / ECSDMxxx / ECSCMxxx. Axis module "Motion" application

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1 EDBCSXM064.6Rc Ä.6Rcä Operating Instructions ECS ECSEMxxx / ECSDMxxx / ECSCMxxx Axis module "Motion" application

2 Please read these instructions before you start working! Follow the enclosed safety instructions. These instructions are valid for ECSxM axis modules, application software V 1.2, as of version: ECS x M xxx x 4 x xxx XX XX XX Device type Hans-Lenze-Straße1 D Aerzen Design E = standard panel mounted unit, IP20 D = push through technique (thermally separated) C = cold plate technique Application M = "Motion" Peak current 004 = 4 A 008 = 8 A 016 = 16 A Fieldbus interface C = CAN system bus 032 = 32 A 048 = 48 A 064 = 64 A L Made in Germany Input 2/PE DC a-aaa/aaav bb.b/bb.ba Output 3/PE AC c-ccc/cccv dd.d/dd.da 0-fffHz Overload ee.ea Type ttttttttttt 1 Id.-No. Prod.-No. Ser.-No. xxxxxxxx yyyyyyyy zzzz ATTENTION WARNING EKZ ECSEAxxxC4BXXXXXVA02 A-SW B-SW Parameter h.h H.H L appareil est sous tension pendant 180s après la coupure de la tension réseau Device is live up to 180s after removing mains voltage 1D74 Ind. Conl. Eq. For detailed information refer to the Instruction Manual Voltage class 4 = 400 V/500 V Technical version B = Standard I = For IT systems Variant Hardware version 1A or higher Version of operating software (B SW) 6.0 or higher Tip! Current documentation and software updates concerning Lenze products can be found on the Internet in the "Services & Downloads" area under 0Fig. 0Tab Lenze Drive Systems GmbH, Hans Lenze Straße 1, D Aerzen No part of this documentation may be reproduced or made accessible to third parties without written consent by Lenze Drive Systems GmbH. All information given in this documentation has been selected carefully and complies with the hardware and software described. Nevertheless, discrepancies cannot be ruled out. We do not take any responsibility or liability for any damage that may occur. Necessary corrections will be included in subsequent editions. 2

3 ECSEA_003A 3

4 Scope of supply Position Description Quantity ECSM... axis module 1 Accessory kit with fixing material corresponding to the design (): "E" standard panel mounted unit "D" push through technique "C" cold plate technique Mounting Instructions 1 Drilling jig 1 Functional earth conductor (only ECSDM...) 1 1 Note! The ECSZA000X0B connectors must be ordered separately. Connections and interfaces Position Description Detailed information X23 Connections DC bus voltage PE 47 x1 x2 LEDs: Status and fault display Automation interface (AIF) for Communication module Operating module (keypad XT) PE connection for AIF X3 Analog input configuration 59 X4 X14 X6 S1 CAN connection MotionBus (CAN) / for ECSxA: System bus (CAN) Interface to higher level control CAN AUX connection System bus (CAN) PC interface/hmi for parameter setting and diagnostics Connections 24 V supply Digital inputs and outputs Analog input "Safe torque off" (formerly "safe standstill") DIP switch CAN address CAN baud rate X7 Resolver connection 74 X8 Encoder connection Incremental encoder (TTL encoder) SinCos encoder X25 Brake control connection 52 X24 Motor connection 51 Status displays LED Operating state Check test Red Green Off On Controller enabled, no fault Off Blinking Controller inhibited (CINH), switch on inhibit Code C0183 Blinking Off Trouble/fault (TRIP) is active Code C0168/1 Blinking On Warning/FAIL QSP is active Code C0168/

5 Contents i 1 Preface and general information How to use these Operating Instructions Terminology used Code descriptions Features of the axis module ECSxM Structure Scope of supply Legal regulations Safety instructions General safety and application notes for Lenze controllers Residual hazards Safety instructions for the installation according to UL or UR Definition of notes used Technical data General data and operating conditions Rated data Current characteristics Increased continuous current depending on the control factor Device protection by current derating Mechanical installation Important notes Mounting with fixing rails (standard installation) Dimensions Assembly steps Mounting with thermal separation (push through technique) Dimensions Assembly steps Mounting in cold plate design Dimensions Assembly steps

6 i Contents 5 Electrical installation Installation according to EMC (installation of a CE typical drive system) Power terminals Connection to the DC bus (+UG, UG) Connection plans Motor connection Motor holding brake connection Connection at capacitor module ECSxK... (optional) Control terminals Digital inputs and outputs Analog input Safe torque off Automation interface (AIF) Wiring of MotionBus/system bus (CAN) Wiring of the feedback system Resolver connection Encoder connection Commissioning Before you start Commissioning steps (overview) Basic settings with GDC Setting of homing Loading the Lenze setting Setting of mains data Selecting the function of the charging current limitation Setting the voltage thresholds Entry of motor data for Lenze motors Holding brake configuration Closing the brake Opening the brake Setting of the feedback system for position and speed control Resolver for position and speed control Codes for setting the resolver feedback Resolver as absolute value encoder Incremental encoder / sin/cos encoder without serial communication Absolute value encoder (Hiperface, single turn/multi turn) Codes for setting the encoder feedback

7 Contents i 6.8 Configuration of control interface (control and status word) Process data to the axis module Process data from the axis module Toggle bit monitoring Entry of machine parameters Setting of homing parameters Homing parameters Homing modes Shifting of the zero position (offset selection) Example: Reference search with linear positioning axis Example: Reference search with continuous positioning axis Selection of the operating mode "Velocity" operating mode "Homing" operating mode Operating mode "Interpolated Position Mode" (IP Mode) "Manual Jog" operating mode Controller enable Following error monitoring Evaluation of hardware limit switches Quick stop (QSP) Operation with servo motors from other manufacturers Entering motor data manually Checking the direction of rotation of the resolver Adjusting current controller Effecting rotor position adjustment Optimising the drive behaviour after start Speed controller adjustment Adjustment of field controller and field weakening controller Resolver adjustment Parameter setting General information Parameter setting with "Global Drive Control" (GDC) Parameter setting with the XT EMZ9371BC keypad Connecting the keypad Description of the display elements Description of the function keys Altering and saving parameters Menu structure

8 i Contents 8 Configuration General information about the system bus (CAN) Structure of the CAN data telegram Communication phases of the CAN network (NMT) Process data transfer Parameter data transfer Addressing of the parameter and process data objects Configuring MotionBus/system bus (CAN) Setting CAN node address and baud rate Defining boot up master in the drive system Setting of boot up time/cycle time Executing a reset node CAN bus synchronisation Axis synchronisation via CAN bus interface Axis synchronisation via terminal Diagnostic codes Monitoring functions (overview) Configuring monitoring functions Reactions Monitoring times for process data input objects Motor temperature (OH3, OH7) Heatsink temperature (OH, OH4) Interior temperature (OH1, OH5) Function monitoring of the thermal sensors (H10, H11) Controller current load (I x t monitoring: OC5, OC7) Motor current load (I2 x t monitoring: OC6, OC8) DC bus voltage (OU, LU) Voltage supply of the control electronics (U15) Motor phases (LP1) Resolver supply cable (Sd2) Motor temperature sensor (Sd6) SinCos encoder (Sd8) Speed beyond the tolerance margin (nerr) Maximum speed exceeded (NMAX) Diagnostics Diagnostics with Global Drive Control (GDC) Diagnostics with Global Drive Oscilloscope (GDO) GDO buttons Diagnostics with GDO Diagnostics with the XT EMZ9371BC keypad

9 Contents i 10 Troubleshooting and fault elimination Fault analysis Fault analysis via the LED display Fault analysis with keypad XT EMZ9371BC Fault analysis with the history buffer Fault analysis via LECOM status words (C0150/C0155) Malfunction of the drive Fault messages Causes and remedies Reset fault messages (TRIP RESET) Appendix Code table Overview of accessories Connectors Shield mounting kit Power supply modules Capacitor modules Components for communication Brake resistors Mains fuses Mains chokes RFI filter Motors Index

10 1 Preface and general information How to use these Operating Instructions 1 Preface and general information 1.1 How to use these Operating Instructions These Operating Instructions assist you in connecting and commissioning the ECSxM... axis modules with multi axis positioning functionality in connection with a master control. They contain safety instructions which must be observed! All persons working on and with the ECSxM... axis modules must have the Operating Instructions available and must observe the information and notes relevant for their work. The Operating Instructions must always be in a complete and perfectly readable condition. 1.2 Terminology used Term Power supply module ECSxE... Capacitor module ECSxK... Axis module Controller ECSxS... ECSxP... ECSxM... ECSxA... Drive system 24 V supply Low voltage supply AIF In the following text used for ECSxE... power supply module Any power supply module of ECS series ECSxK... capacitor module Any capacitor module of ECS series ECSxM... axis module Any axis module of ECS series: ECSxS... application "Speed and Torque" ECSxP... application "Posi and Shaft" ECSxM... application "Motion" ECSxA... application "Application" Drive systems with: ECSxS... / ECSxP... / ECSxM... / ECSxA... axis modules ECSxE... power supply modules ECSxK... capacitor modules Other Lenze drive components Voltage supply of the control card, voltage range V DC (0 V) of the "safe torque off"(formerly "safe standstill"), voltage range V DC (0 V) of the motor holding brake, voltage range V DC (0 V) Automation InterFace Cxxxx/y Subcode y of code Cxxxx (e.g. C0470/3 = subcode 3 of code C0470) Xk/y Terminal y on the plug connector Xk (e.g. X6/B+ = terminal B+ on the plug connector X6) 10

11 Preface and general information Code descriptions Code descriptions Lenze codes are described in the form of tables with the following structure: Column Abbreviation Meaning No. Cxxxx Code no. Cxxxx 1 Subcode 1 of Cxxxx 2 Subcode 2 of Cxxxx Cxxxx Changed parameter of the code or subcode is accepted after pressing. [Cxxxx] Changed parameter of the code or subcode is accepted after pressing if the controller is inhibited. Designation LCD of XT EMZ9371BC keypad Lenze/{Appl.} x Lenze setting: Value at delivery or after loading the Lenze setting with C0002. {xxx...} Deviating application initialisation value: Value at delivery. After loading the Lenze setting with C0002, the application initialisation value is overwritten by the Lenze setting. The application initialisation values can be restored by loading the application software with "Global Drive Loader" (GDL). The column "Important" contains further information Selection 1 {%} 99 Minimum value {unit} maximum value IMPORTANT Short code description Example Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0003 Par save 0 Save parameter set 0 Done Saving completed 1 Save parameter set 1 Non volatile saving of parameter set 1 C1192 Selection of resistance characteristic for PTC 1 Char.: OHM 1000 {0} 0 {1 } Resistance at temperature 1 2 Char.: OHM 2225 Resistance at temperature 2 11

12 1 Preface and general information Features of the axis module ECSxM 1.4 Features of the axis module ECSxM Homing can be selected from 19 modes Brake logic can be connected Switching of operating modes "Velocity Mode" "Homing Mode" "Interpolated Position Mode" (for travel according to setpoint selection) "Manual Jog" Torque feedforward control Fine interpolation Interpolation cycle can be selected between 1 10 ms Sequence co ordination with master control Toggle bit monitoring Status signals selectable via control words Safety function "safe torque off" (formerly "safe standstill") Double CAN ON BOARD: MotionBus (CAN): Control interface "CAN" (PDO1, sync based) System bus (CAN): Interface "CAN AUX" for parameter setting/diagnostics Supported feedback systems: Resolver with and without position storage Encoder (incremental encoder (TTL encoder), sin/cos absolute value encoder) Commissioning and parameter setting with the Lenze parameter setting and operating program "Global Drive Control" (GDC) 12

13 1.5 Structure UG+ UG- UG+ UG- PE PE ECSxM X6 X4 Digital_IO CAN_IO C3160 C3161 C3162 Toggle bit C3152 C3153 Status word Control word Monitor data Drive control Trouble VelMode Init Stand by Homing IP-Mode ManJog C0135 C0576 C0579 C3002 C3008 C3009 C3010 C3011 C3012 C3020 C3021 C3022 C3037 C3038 C3170 C3175 C5000 CAN_SYNC Set position (32 bits) C3165 C3420 C3422 C3421 C3150 C3151 C3180 C3181 C0136 C0150 C3200 C3210 C3211 C5001 C Fig.1 1 Fine interpolation * C0050 Actual position (32 bits) + - * C4001 C0011 C3430 Structure of the ECS application "Motion" C0011 C0497 C0935 C0936 C3010 C3011 C3012 Homing C3030 C3031 C3032 C3033 C0051 C3034 Motor control Position control 1000 s 32 bits alternative TTL encoder Sin/cos encoder Speed control 250 s + + X8 C0019 C0071 C bits Feedback C0070 C0072 C0909 C0030 C0058 C0095 C0098 C0416 C0419 C0420 C0421 C0427 C0490 C0491 C0495 C0540 C3001 X7 R Motor Current/torque control C0053 C0079 C0082 C0083 C s PWM C0018 VEC CTRL U 16 bits C0022 C0023 C0074 C0075 C0076 C0077 C0078 C0080 C0081 C0084 C0085 C0087 C0088 C0089 C0090 C0091 C4018 V M 3~ W PE ECSXA502 Preface and general information Structure 1

14 1 Preface and general information Scope of supply 1.6 Scope of supply The scope of supply of the ECSxM... axis module contains: Basic device Accessory kit with fixing material corresponding to the design: "E" standard panel mounted unit "D" push through technique "C" cold plate technique Mounting Instructions Drilling jig Functional earth conductor (only ECSDM...) Accessories Information on the following accessories can be found in the appendix ( 288). Connectors for power supply modules: ECSZE000X0B capacitor modules: ECSZK000X0B axis modules: ECSZA000X0B ECSZS000X0B001 shield mounting kit (EMC accessories) Communication modules for the automation interface (AIF) ECSxE... power supply module ECSxK... capacitor module Brake resistors Mains fuses Mains chokes RFI filters Motors 14

15 Preface and general information Legal regulations Legal regulations Identification Nameplate CE identification Manufacturer Application as directed Lenze controllers are unambiguously designated by the contents of the nameplate. ECSxM... axis modules Conforms to the EC Low Voltage Directive Lenze Drive Systems GmbH PO box D Hameln must only be operated under the conditions prescribed in these instructions. are components for open and closed loop control of variable speed drives with PM synchronous motors and asynchronous motors. for installation in a machine. for assembly with other components to form a machine. are electrical equipment for the installation in control cabinets or similar closed operating areas. comply with the protective requirements of the EC Low Voltage Directive. are not machines for the purpose of the EC Machinery Directive. are not to be used as domestic appliances, but for industrial purposes only. Drive systems with ECSxM... axis modules comply with the EC Directive "Electromagnetic compatibility" if they are installed according to the guidelines of CE typical drive systems. can be used at public and non public mains. in industrial premises. The user is responsible for the compliance of his application with the EC directives. Any other use shall be deemed inappropriate! Liability The information, data and notes in these instructions met the state of the art at the time of printing. Claims on modifications referring to axis modules and components which have already been supplied cannot be derived from the information, illustrations and descriptions given in these instructions. The specifications, processes and circuitry described in these instructions are for guidance only and must be adapted to your own specific application. Lenze does not take responsibility for the suitability of the process and circuit proposals. Lenze does not accept any liability for damages and failures caused by: Disregarding the Operating Instructions Unauthorised modifications to the axis module Operating errors Improper working on and with the axis module Warranty Terms of warranty: See terms of sales and delivery of Lenze Drive Systems GmbH. Warranty claims must be made to Lenze immediately after detecting the deficiency or fault. The warranty is void in all cases where liability claims cannot be made. 15

16 2 Safety instructions General safety and application notes for Lenze controllers 2 Safety instructions 2.1 General safety and application notes for Lenze controllers (According to: Low Voltage Directive 73/23/EEC) General Depending on their degree of protection, some parts of Lenze controllers (frequency inverters, servo inverters, DC controllers) and their accessory components can be live, moving and rotating during operation. Surfaces can be hot. Non authorised removal of the required cover, inappropriate use, incorrect installation or operation, creates the risk of severe injury to persons or damage to material assets. For more information please see the documentation. All operations concerning transport, installation, and commissioning as well as maintenance must be carried out by qualified, skilled personnel (IEC 364 and CENELEC HD 384 or DIN VDE 0100 and IEC report 664 or DIN VDE 0110 and national regulations for the prevention of accidents must be observed). According to this basic safety information, qualified, skilled personnel are persons who are familiar with the assembly, installation, commissioning, and operation of the product and who have the qualifications necessary for their occupation. Application as directed Drive controllers are components which are designed for installation in electrical systems or machinery. They are not to be used as domestic appliances, but only for industrial purposes according to EN When installing drive controllers into machines, commissioning of these controllers (i.e. the starting of operation as directed) is prohibited until it is proven that the machine corresponds to the regulations of the EC Directive 98/37/EC (Machinery Directive); EN must be observed. Commissioning (i.e. starting of operation as directed) is only allowed when there is compliance with the EMC Directive (89/336/EEC). The controllers meet the requirements of the Low Voltage Directive 73/23/EEC. The harmonised standard EN applies to the controllers. The technical data as well as the connection conditions can be obtained from the nameplate and the documentation. They must be strictly observed. Warning: The controllers are products which can be installed in drive systems of category C2 according to EN These products can cause radio interference in residential areas. In this case, special measures can be necessary. Transport, storage Please observe the notes on transport, storage and appropriate handling. Observe the climatic conditions according to the technical data. 16

17 Safety instructions General safety and application notes for Lenze controllers 2 Installation The controllers must be installed and cooled according to the instructions given in the corresponding documentation. Ensure proper handling and avoid mechanical stress. Do not bend any components and do not change any insulation distances during transport or handling. Do not touch any electronic components and contacts. Controllers contain electrostatically sensitive components, which can easily be damaged by inappropriate handling. Do not damage or destroy any electrical components since this might endanger your health! Electrical connection When working on live controllers, the valid national regulations for the prevention of accidents (e.g. VBG 4) must be observed. Carry out the electrical installation in compliance with the corresponding regulations (e.g. cable cross sections, fuses, PE connection). More detailed information is given in the corresponding documentation. Notes about installation according to EMC regulations (shielding, earthing, filters and cable routing) are included in the documentation. These notes also apply to CE marked controllers. The compliance with limit values required by the EMC legislation is the responsibility of the manufacturer of the machine or system. The controllers must be installed in housings (e.g. control cabinets) to meet the limit values for radio interferences valid at the site of installation. The housings must enable an EMC compliant installation. Observe in particular that e.g. the control cabinet doors should have a circumferential metal connection to the housing. Reduce housing openings and cutouts to a minimum. Lenze controllers can cause a DC residual current in the protective conductor. If a residual current device (RCD) is used as a protective means in the case of direct or indirect contact, only a residual current device (RCD) of type B may be used on the current supply side of the controller. Otherwise, another protective measure, such as separation from the environment through double or reinforced insulation or disconnection from the mains by means of a transformer must be used. Operation If necessary, systems including controllers must be equipped with additional monitoring and protection devices according to the valid safety regulations (e.g. law on technical equipment, regulations for the prevention of accidents). The controller can be adapted to your application. Please observe the corresponding information given in the documentation. After a controller has been disconnected from the voltage supply, all live components and power connections must not be touched immediately because capacitors can still be charged. Please observe the corresponding stickers on the controller. All protection covers and doors must be shut during operation. Note for UL approved systems with integrated controllers: UL warnings are notes that only apply to UL systems. The documentation contains special UL notes. 17

18 2 Safety instructions General safety and application notes for Lenze controllers Safety functions Special controller variants support safety functions (e.g. "safe torque off", formerly "safe standstill") according to the requirements of Annex I No of the EC Directive "Machinery" 98/37/EC, EN Category 3 and EN Strictly observe the notes on the safety functions given in the documentation on the respective variants. Maintenance and servicing The controllers do not require any maintenance, if the prescribed conditions of operation are observed. If the ambient air is polluted, the cooling surfaces of the controller may become dirty or the air vents of the controller may be obstructed. Therefore, clean the cooling surfaces and air vents periodically under these operating conditions. Do not use sharp or pointed tools for this purpose! Waste disposal Recycle metal and plastic materials. Ensure professional disposal of assembled PCBs. The product specific safety and application notes given in these Operating Instructions must be observed! 18

19 Safety instructions Residual hazards Residual hazards Protection of persons Before working on the axis module, check that no voltage is applied to the power terminals, because the power terminals +UG, UG, U, V and W remain live for at least 3 minutes after mains switch off. because the power terminals +UG, UG, U, V and W remain live when the motor is stopped. The heatsink has an operating temperature of > 70 C: Direct skin contact with the heatsink results in burns. The leakage current to PE is > 3.5 ma AC or > 10 ma DC. EN requires a fixed installation. The PE connection must be designed to EN Comply with the additional requirements of EN for high leakage currents. Device protection All pluggable connection terminals must only be connected or disconnected when no voltage is applied! The power terminals +UG, UG, U, V, W, and PE are not protected against polarity reversal. When wiring, observe the polarity of the power terminals! Power must not be converted until all devices of the power system are ready for operation. Otherwise, the input current limitation may be destroyed. Frequent mains switching (e.g. inching mode via mains contactor) can overload and destroy the input current limitation of the axis module, if the axis module is supplied via the ECSXE power supply module and the input current limitation is activated depending on the DC bus voltage (C0175 = 1 or 2). the axis module is not supplied via a power supply module from Lenze. the low voltage supply (24 V) is switched off. Under these operating conditions allow a break of at least 3 minutes between two starting operations! In case of frequent disconnections due to safety reasons, use the safety function Safe torque off (STO). 19

20 2 Safety instructions Residual hazards Motor protection Only use motors with a minimum insulation resistance of û = 1.5 kv, min. du/dt = 5 kv/s. Lenze motors meet these requirements. When using motors with an unknown insulation resistance, please contact your motor supplier. Some settings of the axis module lead to an overheating of the connected motor, e.g. longer operation of self ventilated motors with low speeds. Use PTC thermistors or thermostats with PTC characteristic for motor temperature monitoring. 20

21 Safety instructions 2 Safety instructions for the installation according to U L or U R 2.3 Safety instructions for the installation according to U L or U R Warnings! General markings: Use 60/75 C or 75 C copper wire only. Maximum ambient temperature 55 C, with reduced output current. Markings provided for the supply units: Suitable for use on a circuit capable of delivering not more than 5000 rms symmetrical amperes, 480 V max, when protected by K5 or H Fuses (400/480 V devices). Alternate Circuit breakers (either inverse time, instantaneous trip types or combination motor controller type E) may be used in lieu of above fuses when it is shown that the let through energy (i 2 t) and peak let through current (I p ) of the inverse time current limiting circuit breaker will be less than that of the non semiconductor type K5 fuses with which the drive has been tested. Alternate An inverse time circuit breaker may be used, sized upon the input rating of the drive, multiplied by 300 %. Markings provided for the inverter units: The inverter units shall be used with supply units which are provided with overvoltage devices or systems in accordance with UL840 2nd ed., Table 5.1. The devices are provided with integral overload and integral thermal protection for the motor. The devices are not provided with overspeed protection. Terminal tightening torque of lb in (Nm) Terminal lb in Nm X 21, X 22, X 23, X X4, X6, X X Wiring diagram AWG Terminal AWG X 21, X 22, X 23, X X4, X6, X X

22 2 Safety instructions Definition of notes used 2.4 Definition of notes used The following pictographs and signal words are used in this documentation to indicate dangers and important information: Safety instructions Structure of safety instructions: Danger! (characterises the type and severity of danger) Note (describes the danger and gives information about how to prevent dangerous situations) Pictograph and signal word Danger! Danger! Stop! Meaning Danger of personal injury through dangerous electrical voltage. Reference to an imminent danger that may result in death or serious personal injury if the corresponding measures are not taken. Danger of personal injury through a general source of danger. Reference to an imminent danger that may result in death or serious personal injury if the corresponding measures are not taken. Danger of property damage. Reference to a possible danger that may result in property damage if the corresponding measures are not taken. Application notes Pictograph and signal word Note! Tip! Meaning Important note to ensure troublefree operation Useful tip for simple handling Reference to another documentation Special safety instructions and application notes for UL and UR Pictograph and signal word Warnings! Warnings! Meaning Safety or application note for the operation of a UL approved device in UL approved systems. Possibly the drive system is not operated in compliance with UL if the corresponding measures are not taken. Safety or application note for the operation of a UR approved device in UL approved systems. Possibly the drive system is not operated in compliance with UL if the corresponding measures are not taken. 22

23 Technical data General data and operating conditions 3 3 Technical data 3.1 General data and operating conditions Standards and operating conditions Conformity CE Low Voltage Directive (73/23/EWG) Approvals UL 508C Power conversion equipment Underwriter Laboratories (File No. E132659) for USA and Canada Max. permissible shielded 50 m For rated mains voltage and switching frequency of 8 khz motor cable length Packaging (DIN 4180) Delivery packing Installation Installation in IP20 control cabinet For the "safe torque off" function (formerly "safe standstill"): mounting in IP54 control cabinet Mounting position Vertically suspended Free space above 65 mm below to the sides 65 mm With ECSZS000X0B shield mounting kit: > 195 mm Side by side mounting without any clearance Environmental conditions Climate 3k3 in accordance with IEC/EN Condensation, splash water and ice formation not permissible. Storage IEC/EN K3 ( C) Transport IEC/EN K3 ( C) Operation IEC/EN K3 ( C) Atmospheric pressure: kpa Above +40 C: reduce the rated output current by 2 %/ C. Site altitude m amsl reduce rated output current by 5 %/1000 m above 1000 m amsl. Over 2000 m amsl: use is only permitted in environments with overvoltage category II Pollution VDE 0110 part 2 pollution degree 2 Vibration resistance Accelerational stability up to 0.7 g (Germanischer Lloyd, general conditions) 23

24 3 Technical data General data and operating conditions General electrical data EMC Compliance with EN Noise emission Compliance with limit value class A to EN (achieved with application typical collective filter) Noise immunity Requirements to EN Requirements Standard Severity ESD 1) EN , i. e. 8 kv with air discharge 6 kv with contact discharge High frequency in cables EN V; MHz RF interference (enclosure) EN , i. e. 10 V/m; MHz Burst EN /4, i. e. 2 kv/5 khz Surge (on mains cable) EN , i. e. 1.2/50 s 1 kv phase phase 2 kv phase PE Insulation resistance Overvoltage category III to VDE 0110 Discharge current to PE (to > 3.5 ma AC during operation EN ) Enclosure IP20 for standard mounting (built in unit) Mounting in cold plate technique mounting with thermal separation (push through technique), IP54 on the heatsink side Protective measure against Short circuit in power terminals Motor terminal has a limited protection against short circuit (after short circuit detection, the error message must be reset.) Short circuit in auxiliary circuits Digital outputs: protected against short circuit Bus and encoder systems: limited protection against short circuit (if necessary, monitoring functions can be switched off, in this case, error messages must be reset:) Short to earth (protected against short to earth during operation, limited protection against short to earth on mains power up) Overvoltage Motor stalling Motor overtemperature (input for KTY, I 2 x t monitoring) Protective insulation of control circuits Protective isolation of mains Double/reinforced insulation to EN ) Noise immunity in the above mentioned severities must be guaranteed through the control cabinet. The user must check the compliance with the severities! 24

25 Technical data Rated data Rated data Rated data Type Axis module ECSx004 ECSx008 ECSx016 Output power 400 V mains S N [kva] Data for operation with upstream supply module on mains voltage U mains [V] DC bus voltage U DC bus [V] DC bus current I DC bus [A] Rated output current at 4 khz I r [A] (causes a heatsink temperature of 70 C at an ambient temperature of 20 C) Rated output current at 8 khz (causes a heatsink temperature of 70 C at an ambient temperature of 20 C) I r [A] Max. output current (acceleration current) I max [A] Permanent current at standstill I 0,eff 4 khz [A] (holding current at 90 C, 4 khz) Short time standstill current I 0,eff 4 khz [A] (holding current at 90 C, 4 khz) 2) Short time standstill current I 0,eff 4 khz [A] (holding current at 70 C, 4 khz) 2) Short time standstill current (holding current at 70 C, 8 khz) 2) I 0,eff 8 khz [A] Power loss (operation with rated Inside the device current at 4 khz / 8 khz) P loss [W] Heatsink Max. output frequency f out [Hz] 600 Mass m [kg] Approx ) If the heatsink temperature reaches 70 C, the switching frequency automatically changes to 4 khz. 2) The indicated temperature is the measured temperature of the heatsink (C0061). Application software: S = Speed & Torque P = Posi & Shaft M = Motion A = Application 25

26 3 Technical data Rated data Rated data Type Axis module ECSx004 ECSx008 ECSx016 Output power 400 V mains S N [kva] Data for operation with upstream supply module on mains voltage U mains [V] DC bus voltage U DC bus [V] DC bus current I DC bus [A] Rated output current at 4 khz I r [A] (causes a heatsink temperature of 70 C at an ambient temperature of 20 C) Rated output current at 8 khz (causes a heatsink temperature of 70 C at an ambient temperature of 20 C) I r [A] Max. output current (acceleration current) I max [A] Permanent current at standstill 2) I 0,eff 4 khz [A] (holding current at 90 C, 4 khz) Short time standstill current I 0,eff 4 khz [A] (holding current at 90 C, 4 khz) 2) Short time standstill current I 0,eff 4 khz [A] (holding current at 70 C, 4 khz) 2) Short time standstill current (holding current at 70 C, 8 khz) 2) I 0,eff 8 khz [A] Power loss (operation with rated Inside the device current at 4 khz / 8 khz) P loss [W] Heatsink Max. output frequency f out [Hz] 600 Mass m [kg] Approx. 2.4 Approx ) If the heatsink temperature reaches 70 C, the switching frequency automatically changes to 4 khz. 2) The indicated temperature is the measured temperature of the heatsink (C0061). Application software: S = Speed & Torque P = Posi & Shaft M = Motion A = Application 26

27 Technical data Current characteristics Increased continuous current depending on the control factor Current characteristics Increased continuous current depending on the control factor In the lower speed range the motor does not need the full motor voltage particularly the more powerful ECS axis modules can be permanently operated with increased output current (cp. continuous current I 0,eff 25). I [A] 30.0 I 0 [A] 27.0 ECSxS/P/M/A ECSxS/P/M/A048 I N [A] ECSxS/P/M/A ECSxS/P/M/A ECSxS/P/M/A008 ECSxS/P/M/A Fig % 50 % 100 % U Mot_n / UMot_max Continuous device current, depending on the output voltage for U mains 400 V at 4 khz I r Rated output current of the axis module U Mot_n Actual controller output voltage U Mot_max 0.9 x current mains voltage ECSXA002 The permissible continuous current depends on the control factor of the power output stages, approximately on the ratio of the motor voltage output in the operating point (U Mot_n ) to the maximum possible output voltage (U Mot_max ). Due to voltage drops across the components involved at rated load and a control margin, U Mot_max can be estimated with 90 % of the mains voltage. 27

28 3 Technical data Current characteristics Increased continuous current depending on the control factor The following table represents the connections between mains voltage, DC bus voltage and motor voltage: Mains voltage [U mains ] DC bus voltage [U ZK = U mains x 1.35] Output voltage (motor voltage) nominally achievable for 100 % modulation [U mot = 0.66 x U ZK ] 3 x 230 V AC 310 V DC 3 x 205 V AC 3 x 380 V AC 510 V DC 3 x 340 V AC 3 x 400 V AC 540 V DC 3 x 360 V AC 3 x 415 V AC 560 V DC 3 x 370 V AC 3 x 460 V AC 620 V DC 3 x 415 V AC 3 x 480 V AC 650 V DC 3 x 435 V AC 3 x 528 V AC 712 V DC 3 x 475 V AC For steady state operation in generator mode with increased DC bus voltage or supply from a closed loop controlled DC voltage source, interpolate accordingly between the values given in the table. The increased rated currents are valid for the entire specified voltage range at switching frequencies of 4 khz and 8 khz. Note! If in this connection a heatsink temperature of > 70 C is reached, the drive switches to a switching frequency of 4 khz, independently of the adjusted switching frequency. Tip! The operating threshold of the I x t monitoring is automatically derived from the variable continuous currents. 28

29 Technical data Current characteristics Increased continuous current depending on the control factor 3 Example: The ECS axis module suitable for operation in conjunction with a Lenze motor of type MCS 14L32 is to be determined. Rated motor data Rated motor torque (M mot ) = 17.2 Nm Rated motor speed (n mot ) = 3225 rpm Motor voltage at 3250 rpm (U mot_n3250 ) = 275 V Rated motor current (I mot ) = 15 A Max. motor current (I mot_max ) = 92 A Application data: Max. torque (M max ) = 35 Nm Max. operating speed (n max ) = 2500 rpm An effective process power (P eff ) of 4.5 kw arises on the basis of the Mn diagram. The drive rating results in an effective motor current (I Mot_eff ) of 14.8 A. A first estimation based on the rated current of the ECS axis module would probably lead to selecting the ECSxM048 module with a rated current of 17.0 A. However, if we take into account the increased continuous current for smaller control factors, the more cost effective ECSxM032 axis module with a rated current of 12.7 A can be used here. When the MCS 14L32 is operated with 2500 rpm, the real motor voltage is (U Mot_n2500 ): U Mot_n2500 U Mot_n3250 n max n 275V 2500rpm 212V Mot 3250rpm This leads to the following max. control factor (α max ) of the axis module: max U Mot_n V % U max 360V Using the current characteristic of Fig.3 1 ( 27), a continuous current of 15.5 A can be determined for the ECSxM032 axis module when the control factor (α max ) is 59 %. Result: Under the conditions mentioned above the MCS 14L32 Lenze motor can be operated continuously on the ECSxM032 axis module. 29

30 3 Technical data Current characteristics Device protection by current derating Device protection by current derating The maximum output current is limited. With output frequencies < 5 Hz the limitation depends on the heatsink temperature. I out I max C C 0.38 Fig Current derating characteristics Operation with switching frequency = 8 khz (C0018 = 1). If the current exceeds the characteristic, the switching frequency is automatically changed to 4 khz (e.g. for higher torque in acceleration processes). Operation with switching frequency = 4 khz (C0018 = 0). The current limitation follows the characteristic. With output frequencies < 5 Hz and heatsink temperatures between 70 and 90 C the current limit is steplessly adjusted in the range. f out [Hz] ECSXA024 Type Switching frequency 8 khz I max [A] Switching frequency 4 khz f out > 5 Hz f out 0 Hz f out > 5 Hz f out 0 Hz 70 C f out 0 Hz 90 C ECSxM ECSxM ECSxM ECSxM ECSxM ECSxM

31 Mechanical installation Important notes 4 4 Mechanical installation 4.1 Important notes Axis modules of series ECS feature enclosure IP20 and, for this reason, are intended for installation in control cabinets. If the cooling air contains pollutants (dust, fluff, grease, aggressive gases): Take suitable preventive measures, e.g. separate air duct, installation of filters, regular cleaning. Possible mounting positions: Vertically at the mounting plate DC bus connections (X23) at the top Motor connection (X24) at the bottom Maintain the specified free spaces above and below to other installations! If the ECSZS000X0B shield mounting kit is used, an additional clearance is required. Ensure unimpeded ventilation of cooling air and outlet of exhaust air. Several modules of the ECS series can be installed in the control cabinet next to each other without any clearance. The mounting plate of the control cabinet must be electrically conductive. must not be varnished. In the case of continuous vibrations or shocks use shock absorbers. 31

32 4 Mechanical installation Mounting with fixing rails (standard installation) Dimensions 4.2 Mounting with fixing rails (standard installation) Dimensions Note! Mounting with ECSZS000X0B shield mounting kit: Mounting clearance below the module > 195 mm 65 mm h g h g d d1 b d d1 b 65 mm e a g a g Fig.4 1 Dimensions for "panel mounted" design ECSxA005 Axis module Dimensions [mm] Type Size a b d d1 e h g ECSEM004 ECSEM008 ECSEM016 ECSEM032 ECSEM048 ECSEM ) max. 212 mm, depending on the plugged on communication module ) (M6) 32

33 Mechanical installation Mounting with fixing rails (standard installation) Assembly steps Assembly steps How to install the axis module: 1. Prepare the fixing holes on the mounting surface. Use the drilling jig for this purpose. 2. Take the fixing rails from the accessory kit in the cardboard box. 3. Push the rails into the slots of the heatsink: From above: Push in the long side. From below: Push in the short side. 4. Attach the axis module to the mounting surface. 33

34 4 Mechanical installation Mounting with thermal separation (push through technique) 4.3 Mounting with thermal separation (push through technique) For the push through technique the rear panel of the control cabinet must be a steel plate with a thickness of at least 2 mm. The edges of the mounting cutout and the fixing holes for the clamps must be slightly curved inwards (towards the axis module). Cooling With the separated heatsink the heat generation in the control cabinet can be reduced. Distribution of the power loss: approx. 65 % via separated cooler approx. 35 % in the inside of the axis module Protection class of the separated cooler: IP54 The sealing surface at the heatsink of the axis module must rest completely against the mounting plate. Use a liquid thread sealant to bond the screws of the clamps. For sufficient cooling of the drive system: Air flow behind the rear panel of the control cabinet must be 3 m/s (e.g. by means of a collective fan). With sufficient cooling, the rated data of the axis modules remain valid. 34

35 Mechanical installation Mounting with thermal separation (push through technique) Dimensions Dimensions Note! Mounting with ECSZS000X0B shield mounting kit: Mounting clearance below the module > 195 mm Fig.4 2 Dimensions for "push through design" Z Mounting cutout (a1 x b1), 36 ECSXA007 Axis module Dimensions [mm] Type Size a a1 b b1 c1 d e e1 g h ECSDM004 ECSDM008 ECSDM016 ECSDM032 ECSDM048 ECSDM ) max. 145 mm, depending on the plugged on communication module ) 67 M

36 4 Mechanical installation Mounting with thermal separation (push through technique) Dimensions Dimensions of mounting cutout Note! Mounting with shield mounting kit ECSZS000X0B001: Clearance below the mounting cutout > 220 mm a1 a1 90 mm 60 mm b1 g g d b1 h c1 c1 ECSXA063 Fig.4 3 Dimensions of mounting cutout Mounting surface Mounting cutout for size Mounting cutout for size Axis module Dimensions [mm] Type Size a1 b1 c1 d g h ECSDM004 ECSDM008 ECSDM ECSDM M ECSDM048 ECSDM

37 Mechanical installation Mounting with thermal separation (push through technique) Assembly steps Assembly steps How to mount the axis module: 1. Prepare the fixing holes for the wire clamps on the mounting area. For this purpose, apply a drilling jig. 2. Prepare mounting cutout. The edges of the mounting cutout and the fixing holes for the wire clamps have to be slightly arched inwardly (to the axis module). 3. Brush the threads of the screws for the wire clamps with liquid thread seal. 4. Fix the wire clamps together with the functional earth conductor supplied (Fig.4 4). The functional earth conductor is part of the scope of supply of the ECSDM...axis modules. 5. Push the axis module into the mounting cutout. 6. Engage axis module in the wire clamp at the top and the bottom. 7. Connect the functional earth conductor to the axis module (Fig.4 4). Note! Fixing the functional earth conductor to the ECSDM... axis module is required for a better electromagnetic compatibility (EMC). Fig.4 4 Functional earth conductor at the axis module ECSDM... Functional earth conductor ECSXA081 37

38 4 Mechanical installation Mounting in cold plate design 4.4 Mounting in cold plate design The axis modules ECSC... are intended for mounting in cold plate design (e.g. on collective coolers). Requirements for collective coolers The following requirements must be met to ensure a safe operation of the axis modules: Good thermal contact with the cooler The contact surface between collective cooler and axis module must be at least as large as the cooling plate of the axis module. Smooth contact surface, max. deviation 0.05 mm. Connect the collective cooler with all specified screwed connections to the axis module. Maintain the thermal resistance R th according to the table. The values apply for operating the axis modules under rated conditions. Axis module Power to be dissipated Heatsink environment Type Ploss [W] R th [k/w] ECSCM ECSCM ECSCM ECSCM ECSCM ECSCM Ambient conditions: Furthermore the rated data regarding the ambient temperature and the derating factors at increased temperature apply to the axis modules ( 23 et seqq.). Temperature of the cooling plate ("Cold Plate"): max. +85 C 38

39 Mechanical installation Mounting in cold plate design Dimensions Dimensions Note! Mounting with ECSZS000X0B shield mounting kit: Mounting clearance below the module > 195 mm 65 mm g a a1 g a a1 65 mm d b b e c1 g c1 g Fig.4 5 Dimensions for "cold plate design" ECSXA009 Axis module Dimensions [mm] Type Size a a1 b c1 d e g ECSCM004 ECSCM008 ECSCM016 ECSCM032 ECSCM048 ECSCM ) max. 157 mm, depending on the plugged on communication module ) M6 39

40 4 Mechanical installation Mounting in cold plate design Assembly steps Assembly steps Fig.4 6 Mounting for "cold plate design" Proceed as follows to mount the axis module: 1. Prepare the fixing holes on the mounting plate. Use a drilling jig for this purpose. 2. Clean and degrease the contact area of collective cooler and heatsink of the axis module (e.g. with methylated spirit). 3. Screw the support onto the collective cooler. 4. Insert the axis module from above into the support and fasten the two stud bolts with Nm. ECSXA030 Note! Penetration depth of the screws into the collective cooler: approx. 15 mm! Tip! The heat transfer resistance is reduced if following step 2. a thin layer of heat conducting paste is applied to the contact surface or heat conducting foil is used. 40

41 Electrical installation Installation according to EMC (installation of a CE typical drive system) 5 5 Electrical installation 5.1 Installation according to EMC (installation of a CE typical drive system) General information The electromagnetic compatibility of a machine depends on the type of installation and care taken. Especially consider the following: Structure Filters Shielding Earthing For diverging installations, the evaluation of the conformity to the EMC Directive requires a check of the machine or system regarding the EMC limit values. This for instance applies to: Use of unshielded cables Use of collective interference filters instead of the assigned RFI filters Operation without RFI filters The compliance of the machine application with the EMC Directive is in the responsibility of the user. If you observe the following measures, you can assume that the machine will operate without any EMC problems caused by the drive system, and that compliance with the EMC Directive and the EMC law is achieved. If devices which do not comply with the CE requirement concerning noise immunity EN are operated close to the axis modules, these devices may be electromagnetically affected by the axis modules. 41

42 5 Electrical installation Installation according to EMC (installation of a CE typical drive system) Structure Connect the power supply modules, capacitor modules (optional), axis modules, RFI filters, and mains chokes to the earthed mounting plate with a surface as large as possible. Mounting plates with conductive surfaces (zinc coated or stainless steel) allow permanent contact. Painted plates are not suitable for an EMC compliant installation. If you use the ECSxK... capacitor module: Install the capacitor module between the power supply module and the axis module(s). If the total cable length in the DC bus connection is > 5 m, install the capacitor module as close as possible to the axis module with the greatest power. Use of several mounting plates: Connect as much surface of the mounting plates as possible (e.g. with copper bands). Ensure the separation of motor cable and signal or mains cable. Avoid a common terminal/power strip for the mains input and motor output. Lay the cables as close as possible to the reference potential. Freely suspended cables act like aerials. Filters Only use RFI filters and mains chokes which are assigned to the power supply modules: RFI filters reduce impermissible high frequency interference to a permissible value. Mains chokes reduce low frequency interferences which depend on the motor cables and their lengths. 42

43 Electrical installation Installation according to EMC (installation of a CE typical drive system) 5 Shielding Connect the motor cable shield to the axis module with the ECSZS000X0B shield mounting kit. extensively to the mounting plate below the axis module. Recommendation: For the shield connection, use ground clamps on bare metal mounting surfaces. If contactors, motor protecting switches or terminals are located in the motor cable: Connect the shields of the connected cables to the mounting plate, too, with a surface as large as possible. Connect the shield in the motor terminal box or on the motor housing extensively to PE: Metal glands at the motor terminal box ensure an extensive connection of the shield and the motor housing. Shield the control cables: Connect both shield ends of the digital control cables. Connect one shield end of the analog control cables. Always connect the shields to the shield connection at the controller over the shortest possible distance. Using the axis modules in residential areas: Additionally dampen the shield in order to limit the interfering radiation: 10 db. This can be realised by using standard, closed, metallic, and earthed control cabinets or boxes. Earthing Earth all metallically conductive components (e. g. power supply module, capacitor module, axis module, RFI filter, motor filter, mains choke) using suitable cables connected to a central point (PE bar). Maintain the minimum cross sections prescribed in the safety regulations: For the EMC, not the cable cross section is important, but the surface of the cable and the contact with a cross section as large as possible, i.e. large surface. 43

44 5 Electrical installation Power terminals 5.2 Power terminals Fig.5 1 Plug connectors for power terminals ECSXA080 Danger! Dangerous voltage The discharge current to earth (PE) is > 3.5 ma AC or > 10 ma DC. Possible consequences: Death or severe injuries when the device is touched in the event of a fault. Protective measures: Implement the actions required in the EN Especially: Fixed installation PE connection must confirm to standards (PE conductor diameter 10 mm 2 or PE conductor must be connected twice) Stop! No device protection in the event of too high mains voltages The mains input is not fused internally. Possible consequences: Destruction of the device if the mains voltage is too high. Protective measures: Observe the max. permissible mains voltage. Fuse the device correctly on the supply side against mains fluctuations and voltage peaks. 44

45 Electrical installation Power terminals 5 All power connections are plug connections and are coded. The ECSZA000X0B connectors must be ordered separately. Installation of the cables according to EN The cables used must comply with the approvals required at the site of use (e.g. VDE, UL, etc.). Assignment of the plug connectors Plug connector/terminal X23 X23/+UG X23/+UG X23/ UG X23/ UG X23/PE X23/PE X24 Function DC bus voltage connection Positive supply of DC bus voltage Negative supply of DC bus voltage Earth connection Motor connection Electrical data Application and type dependent V A ( 25) X24/U Motor phase U Application and type dependent X24/V Motor phase V V A ( 25) X24/W Motor phase W X24/PE X25 Earth connection Motor holding brake connection X25/BD1 Brake connection V DC, X25/BD2 Brake connection max. 1.5 A Cable cross sections and screw tightening torques Cable type Wire end ferrule Possible cable cross sections Plug connectors X23 and X24 Rigid mm 2 (AWG ) Without wire end ferrule mm 2 (AWG ) Flexible With wire end ferrule mm 2 (AWG ) With TWIN wire end ferrule mm 2 (AWG ) Plug connector X25 Flexible Without wire end ferrule mm 2 (AWG ) Tightening torque Nm ( lb in) Nm ( lb in) Stripping length 5 mm 5 mm 45

46 5 Electrical installation Power terminals Shielded cables The following factors decisively determine the effect of the shielded cables: Good shield connection Ensure a contact surface as large as possible Low shield resistance Only use shields with tin plated or nickel plated copper braids (shields with steel braids cannot be used). High overlap rate of the braid At least % with 90 overlap angle The ECSZS000X0B shield mounting kit includes a wire clamp and shield sheet. 46

47 Electrical installation Power terminals Connection to the DC bus (+U G, U G ) Connection to the DC bus (+U G, U G ) Stop! No device protection for voltage surges of the DC bus In passive axis modules (without 24 V supply) the charging connection can be overloaded by voltage surges of the DC bus. Possible consequences: Destruction of the device Protective measures: As a basic principle, supply all axis modules in the DC bus connection with a 24 V control voltage. If the total cable length is > 20 m, install an axis module or a capacitor module directly at the power supply module. Design the ±U G cables twisted and as short as possible. Ensure short circuit proof routing! Cable length (module module) > 30 cm: install ±U G cables shielded. Cable cross sections Cable length 1) Wire end ferrule Cable cross section Up to 20 m Without wire end ferrule 6 mm 2 With wire end ferrule (AWG 10) Without wire end ferrule > 20 m 10 mm With wire end ferrule 2 (AWG 8) Use pin end connectors for wiring! 1) Respective cable length from module to module Tightening torque Nm ( lb in) Stripping length 5 mm 47

48 5 Electrical installation Power terminals Connection to the DC bus (+U G, U G ) Fuses When ECSxE series power supply modules with protection on the supply side are used, the DC bus supply does not need to be fused. When ECS axis modules are supplied by devices of the 82xx and 93xx series with a continuous DC current > 40 A, install the following fuses between the supplying device and the ECS devices: Fuse Support Value [A] Lenze type Lenze type 50 EFSGR0500ANIN EFH20007 Warnings! Use UL approved cables, fuses and fuse holders only. UL fuse: Voltage V Tripping characteristic "H", "K5" or "CC" Replacing defective fuses Danger! Hazardous electrical voltage Components can carry hazardous voltages until up to 3 minutes after power off. Possible consequences: Death or severe injuries when touching the device. Protective measures: Replace fuses in the deenergised state only. Set controller inhibit (CINH) for all axis modules in DC bus operation and disconnect all power supply modules from the mains. 48

49 Electrical installation Power terminals Connection plans Connection plans Observe... the notes in the detailed documentation of the power supply module. Mimimum wiring with power supply module ECSEE... / ECSDE... A brake resistor is integrated in the ECSEE... and ECSDE... power supply modules. The internal brake resistor is used with the following jumpers: L1 L2 L3 N from X22/BR0 to X22/+UG from X6/T1 to X6/T2 K1 F4 F1...F3 Z1 Off On K1 K1 L1 L2 L3 PE X21 ECSEE... ECSDE... BR0 BR1 +UG +UG -UG PE Rb X22 +UG +UG -UG -UG PE PE X23 ECSxS/P/M/A... +UG +UG -UG -UG PE PE X23 ECSxS/P/M/A... T1 T2 X6... X25 BD1 BD2 X24 U V W PE X7 X25 BD1 BD2 X24 U V W PE X7 Fig M 3~ R 2 6 M 3~ R 2 Interconnected power system with internal brake resistor HF shield termination by large surface connection to functional earth (see Mounting Instructions for ECSZS000X0B shield mounting kit) Twisted cables K1 Mains contactor F1... F4 Fuse Z1 Mains choke / mains filter, optional Rb Brake resistor System cable feedback ECSXA011 49

50 5 Electrical installation Power terminals Connection plans Mimimum wiring with power supply module ECSCE... Based on the design, the ECSCE... power supply module is not provided with an integrated brake resistor. For this reason, install an external brake resistor of the ERBM..., ERBS... or ERBD... series: L1 L2 L3 N Connect the brake resistor to X22/BR1 and X22/+UG. Connect a thermal detector (NC contact) to X6/T1 and X6/T2. K1 F4 F1...F3 Z1 Rb K1 Off On L1 L2 L3 PE X21 ECSCE... BR0 BR1 +UG +UG -UG PE X22 +UG +UG -UG -UG PE PE X23 ECSxS/P/M/A... +UG +UG -UG -UG PE PE X23 ECSxS/P/M/A... K1 Rb T1 T2 X6... X25 BD1 BD2 X24 U V W PE X7 X25 BD1 BD2 X24 U V W PE X7 Fig M 3~ R 2 6 M 3~ R 2 Interconnected power system with external brake resistor HF shield termination by large surface connection to functional earth (see Mounting Instructions for ECSZS000X0B shield mounting kit) Twisted cables K1 Mains contactor F1... F4 Fuse Z1 Mains choke / mains filter, optional Rb Brake resistor System cable feedback ECSXA012 50

51 Electrical installation Power terminals Motor connection Motor connection Fig.5 4 Motor and motor holding brake connection ECSXA010 Motor cables Use low capacitance motor cables. Capacitance per unit length: Core/core: max. 75 pf/m Core/shield: max. 150 pf/m Length: max. 50 m, shielded The cross section of the motor cables are selected according to the motor standstill current (I 0 ) when using synchronous motors or according to the rated motor current (I N ) for asynchronous motors. Length of the unshielded ends: mm (depending on the cable cross section) Lenze system cables meet these requirements. Use the ECSZS000X0B shield mounting kit for EMC compliant wiring. Further information... with regard to the EMC compliant wiring can be found in the Mounting Instructions of the ECSZS000X0B shield mounting kit. 51

52 5 Electrical installation Power terminals Motor holding brake connection Motor holding brake connection The motor holding brake is connected to X25/BD1 and X25/BD2 and is supplied with low voltage via the terminals X6/B+ and X6/B : V DC, max.1.5 A Stop! Protect X6/B+ with an F 1.6 A fuse. If no appropriate voltage (incorrect height, incorrect polarity) is applied to the brake, it engages and can be overheated and damaged by the motor that keeps rotating Spark suppressor A spark suppressor is integrated into the axis module for the motor holding brake Brake monitoring The connection of the motor holding brake can be monitored for voltage failure and cable breakage if monitoring is activated under C0602. Motor holding brake open (inactive): The connection of the motor holding brake is monitored with regard to voltage failure and cable breakage: Threshold value for cable breakage: 140 ma 10 % Threshold value for voltage failure: +4 V 10 % Motor holding brake closed (active): The connection of the motor holding brake is monitored with regard to cable breakage if the threshold value of the voltage supply X6/B+ and X6/B exceeds 4 V. 52

53 +_ Electrical installation Power terminals Motor holding brake connection Requirements on the brake cables Use Lenze system cable with integrated brake cable. The shielding of the brake cable must be separated. Length: max. 50 m If a separately installed brake cable is required, lay it in a shielded manner. Note! By the current monitoring, an ohmic voltage loss of 1.5 V along the motor cable is produced. The voltage loss can be compensated by a higher voltage at the cable entry. The following applies to Lenze system cables: U K [V] U B [V] 0, 08 V m A L L[m] I B [A] 1, 5[V] U K U B L L I B Voltage for compensating the voltage loss at 6X/B+ and X6/B [V] Rated operating voltage of the brake [V] Cable length [m] Brake current [A] 1.5 A X6 B+ B- X25 BD2 BD1 F 1.6 A + _ V DC max. 1.5 A M 3~ ECSXA017 Fig.5 5 Connection of the motor holding brake to X25 HF shield termination by large surface connection to functional earth (see Mounting Instructions of the ECSZS000X0B shield mounting kit) 53

54 5 Electrical installation Power terminals Connection at capacitor module ECSxK... (optional) Connection at capacitor module ECSxK... (optional) Observe... the notes in the detailed documentation of the capacitor module. L1 L2 L3 N K1 F4 Off On K1 K1 F1...F3 Z1 L1 L2 L3 PE BR0 BR1 +UG +UG -UG PE +UG +UG -UG -UG PE PE +UG +UG -UG -UG PE PE X21 X22 X23 X23 T1 T2 DI1 DI2 DO1 D24 +24V GND ECSxE... ECSxK... ECSxS/P/M/A... X6 X26 X25 X24 X7 BD1 BD2 U V W PE GND 6 M 3~ R 2-24VDC + Fig.5 6 Wiring of capacitor module ECSxK... HF shield termination by large surface connection to functional earth (see Mounting Instructions for ECSZS000X0B shield mounting kit) Twisted cables K1 Mains contactor F1... F4 Fuse Z1 Mains choke / mains filter, optional Contactor relay System cable feedback Terminal X6/SI1 of the connected axis modules (controller enable/inhibit) ECSXX004 54

55 Electrical installation Control terminals Control terminals Fig.5 7 Plug connectors for control terminals (X6) ECSXA070 For the supply of the control electronics an external 24 V DC voltage at terminals X6/+24 and X6/GND is required. Stop! The control cables must always be shielded to prevent interference injections. The voltage difference between X6/AG, X6/GND and PE of the axis module may maximally amount to 50 V. The voltage difference is limited by: overvoltage limiting components or direct connection of X6/AG and X6/GND to PE. The wiring has to ensure that for X6/DO1 = 0 (LOW level) the connected axis modules do not draw energy from the DC bus. Otherwise, the power supply module may be damaged. Shield connection of control cables and signal cables The plate on the front of the device serves as the mounting place (two threaded holes M4) for the shield connection of the signal cables. The screws used may extend into the inside of the device by up to 10 mm. For optimum contact of the shield connection, use the wire clamps from the ECSZS000X0B shield mounting kit. 55

56 - = + 5 Electrical installation Control terminals L1 L2 L3 PE X21 BR0 BR1 +UG ECSxE... +UG -UG X22 PE +UG +UG -UG -UG PE PE X23 ECSxS/P/M/A... Fig.5 8 T1 T2 DI1 DI2 X6 DO1 D24 +24V GND +24 VDC GND DO1 DI1 DI2 DI3 DI4 AI+ AI- X6 AG 24 VDC System: control signals with internal brake resistor HF shield termination by large surface connection to functional earth (see Mounting Instructions for ECSZS000X0B shield mounting kit) Contactor relay Voltage supply of motor holding brake V DC, max.1.5 A Safe torque off (formerly "safe standstill") Controller enable/inhibit V = GND S24 SO SI1 SI2 B+ B- F1,6A U ECSXA013 Assignment of the plug connectors Plug connector X6 Terminal Function Electrical data X6/+24 Low voltage supply of the control electronics V DC, 0. A (max. 1 A) X6/GND Reference potential of low voltage supply for starting current of 24 V: max. 2 A for 50 ms X6/DO1 Digital output 1 24 V DC, 0.7 A (max. 1.4 A) short circuit proof X6/DI1 X6/DI2 Digital input 1 Digital input 2 LOW: V; ma X6/DI3 Digital input 3 HIGH: V; ma X6/DI4 Digital input 4 Input current at 24 V DC: 8 ma per input X6/AI+ Analog input + Adjustable with jumper strip X3: X6/AI Analog input V, max. 2 ma ma X6/AG Reference potential of analog input (internal Resolution: 11 bits + sign ground) X6/B+ Brake supply V DC max. 1.5 A Set brake voltage so that the permissible X6/B Brake supply voltage at the brake is not under run or exceeded otherwise malfunction or destruction! X6/S24 X6/SO X6/SI1 X6/SI2 Connection of "safe torque off" (formerly "safe standstill") 60 56

57 Electrical installation Control terminals 5 Cable cross sections and screw tightening torques Cable type Wire end ferrule Cable cross section Starting torque Stripping length flexible Without wire end ferrule Insulated with wire end ferrule mm 2 (AWG ) mm 2 (AWG ) Nm ( lb in) We recommend control cables with a cable cross section of 0.25 mm 2. 5 mm 57

58 5 Electrical installation Control terminals Digital inputs and outputs Digital inputs and outputs Stop! If an inductive load is connected to X6/DO1, a spark suppressor with a limiting function to max. 50 V 0 % must be provided. GNDext 47k 1k 3k3 3k3 3k3 3k3 1.5 A X6 DI1 DI2 DI3 DI4 GND DO1 +24 _ 24 VDC = + Fig.5 9 Digital inputs and outputs at X6 HF shield termination by large surface connection to functional earth (see Mounting Instructions for ECSZS000X0B shield mounting kit) ECSXA014 Terminal assignment Plug connector X6 Terminal Function Level Reaction X6/DI1 Quick stop (QSP) LOW The drive is decelerated to standstill within the deceleration time set in C0105. HIGH The motor follows the setpoint selection. X6/DI2 Reference switch/ LOW No reaction touch probe sensor HIGH Activation of reference switch/touch probe sensor (both edge active) X6/DI3 Positive hardware limit switch LOW The controller reports the activation of the positive hardware limit switch to the control. A further safety measure can be implemented by wiring the emergency off circuit. HIGH No reaction X6/DI4 X6/DO1 Negative hardware limit switch Switching between reference switch and touch probe sensorat X6/DI2 LOW HIGH LOW HIGH The controller reports the activation of the negative hardware limit switch to the control. A further safety measure can be implemented by wiring the emergency off circuit. No reaction X6/DI2 = reference switch X6/DI2 = touch probe sensor Note: A switch over is only required for homing modes 6 and 7 ( 117). 58

59 = = Electrical installation Control terminals Analog input Analog input 82k5 82k5 X R GND 3.3 nf 3.3 nf Fig.5 10 X6 AI- AG AI+ Analog input at X6 HF shield termination by large surface connection to functional earth (see Mounting Instructions for ECSZS000X0B shield mounting kit) ECSXA015 Analog input configuration Set via C0034 whether the input is to be used for a master voltage or a master current. Set jumper bar X3 according to setting in C0034: Stop! Do not plug the jumper on 3 4! The axis module cannot be initialised like this. Jumper strip X3 Setting Measuring range open Jumper on 1 2: parking position 5 6 closed C0034 = 0 Level: V Resolution: 5 mv (11 bits + sign) Scaling: 10 V % C0034 = 1 Level: ma Resolution: 20 A (10 bits without sign) Scaling: 4 ma 0 0 % 20 ma % C0034 = 2 Level: ma Resolution: 20 A (10 bits + sign) Scaling: 20 ma % 59

60 5 Electrical installation Control terminals Safe torque off Safe torque off The axis modules support the safety function "safe torque off" (formerly "safe standstill"), "protection against unexpected start up", in accordance with the requirements of control category 3 of EN 954 part 1 and part 2 (from : EN ISO 13849). For this purpose, the axis modules are provided with two independent safety paths. Control category 3 is reached if the output signal at X6/SO is additionally verified Implementation In the axis module, the "safe torque off" connection is implemented with optocouplers. The optocouplers isolate the following areas electrically from each other: The digital inputs and outputs: input X6/SI1 (controller enable/inhibit) input X6/SI2 (pulse enable/inhibit) brake output X6/B+, B output X6/SO ("safe torque off" active/inactive) The circuit for the internal control The final power stage X6 Sl1 Sl2 S24 SO GND B+ >1 µp U V W X Y Z & & & & & & X2 U V W B- X25 BD2 BD1 Fig.5 11 Implementation of the "safe torque off" function Area 1: Inputs and outputs Area 2: Circuit for the internal control Area 3: Power output stage ECSXA100 Stop! Use insulated wire end ferrules when wiring the "safe torque off" circuits to X6. 60

61 Electrical installation Control terminals Safe torque off Functional description The "safe torque off" state can be initiated any time via the input terminals X6/SI1 (controller enable/inhibit) and X6/SI2 (pulse enable/inhibit). For this purpose a LOW level has to be applied at both terminals: X6/SI1 = LOW (controller inhibited): The inverter is inhibited via the microcontroller system. X6/SI2 = LOW (pulses inhibited): The supply voltage for the optocouplers of the power section driver is switched off, i. e. the inverter can no longer be enabled and controlled via the microcontroller system. The input signal at X6/SI2 to the hardware is additionally directed to the microcontroller system and is evaluated for the state control there. For the external further processing a HIGH level is output for the state "safe torque off active" at the digital output X6/SO. The control of the inverter thus is prevented by two different methods that are independent of each other. Therefore an unexpected start up by the motor is avoided. 61

62 5 Electrical installation Control terminals Safe torque off Additional safety instructions Installation/commissioning Only qualified personnel is permitted to install and set up the "safe torque off" function. All control components (switches, relays, PLC,...) and the control cabinet must comply with the requirements of EN and EN (from : EN ISO 13849). These include among other things: Switch, relay with enclosure IP54. Control cabinet with enclosure IP54. Gather all further requirements from EN and EN (from : EN ISO 13849). Wiring with insulated wire end ferrules is essential. All safety relevant cables (e. g. control cable for the safety relay, feedback contact) must be installed outside the control cabinet, e. g. in the cable duct. It must be ensured that short circuits between the single cables cannot occur. For further measures see EN (of : EN ISO 13849), table D4. When an external force is likely to act with the "Safe torque off" function (e.g. sagging of hanging loads) additional measures have to be provided (e.g. mechanical brakes). Danger! When using the "Safe torque off" function, additional measures are required for "Emergency off"! There is neither an electrical isolation between motor and axis module nor a "service switch" or a "repair switch". Possible consequences: Death or severest injuries Destruction or damage of the machine/drive Protective measures: An "Emergency off" requires an electrical isolation of the cable path to the motor, e.g. by means of a central mains contactor with "Emergency off" connection. During operation After installation the operator must check the "Safe torque off" function. The function check must be repeated at regular intervals, after one year at the latest. 62

63 Electrical installation Control terminals Safe torque off Technical data Terminal assignment Plug connector X6 Terminal Function Level Electrical data X6/S24 Low voltage supply V DC 0.7 A X6/SO "Safe torque off" feedback output LOW HIGH During operation "Safe torque off" active 24 V DC 0.7 A (max. 1.4 A) Short circuit proof X6/SI1 Input 1 (controller enable/inhibit) LOW Controller inhibited LOW level: HIGH Controller enabled X6/SI2 Input 2 (pulse enable/inhibit) LOW Pulses for power section are inhibited HIGH Cable cross sections and screw tightening torques Pulses for power section are enabled V ma HIGH level: V ma Input current at 24 V DC: 8 ma per input Cable type Wire end ferrule Cable cross section Tightening torque Stripping length Flexible With insulated wire end ferrule mm 2 (AWG ) Nm ( lb in) 5 mm 63

64 5 Electrical installation Control terminals Safe torque off Minimum wiring In order to reach the control category 3, the signal at X6/SO must be verified additionally. This requires external wiring. The external wiring must be adapted to the existing safety concepts and checked for a correct operation. Tip! For an example of wiring with an electronic safety control unit for category 3, please see 68. "Safe torque off" with multiple contact switches This circuit shows the minimum external wiring of the axis module with multiple contact switches for a motor with brake. 24VDC S S X6 Sl1 Sl2 S24 SO GND B+ B- H1 Y1 X25 BD2 BD1 Fig.5 12 GND Minimum external wiring with multiple contact switches ECSXA101 Stop! Observe the reaction of the drive when activating controller enable and/or pulse enable (X6/SI1 or SI2 = HIGH level): The motor brake is applied immediately. This can lead to high wear on the motor holding brake (see data sheet of the brake). If the brake monitoring is active (C0602 = 0), TRIP "Rel1" is set. Before recommissioning, the TRIP must be reset. 64

65 Electrical installation Control terminals Safe torque off 5 Requirements for external wiring with multiple contact switches: The switches S1 and S2 must have at least three contacts: At least one NC contact and two NO contacts being all electrically independent and positively driven. The contacts must not be bridged. The switches S1 and S2 must be mechanically separated to avoid that all contacts switch at the same time when being operated. The NO contacts of S1 and S2 may only close when the NC contacts are open. NO contacts and NC contacts must not be operated at the same time. Design S1 and S2 for a voltage of 24 V DC. If a higher voltage occurs in the electrical environment, the switches must have an insulation voltage. This insulation voltage must at least correspond to the highest voltage that can occur in case of a fault. Ensure that two channels are available for control category 3: At every switch off (even single channel) via contacts 13/14 of switches S1 and S2, the brake supply is interrupted and the brake is applied. In addition, the internal brake relay must be switched off by the application. The output supply (X6/S24) via NC contacts 11/12 of switches S1 and S2 is only switched through if both controller channels are switched off. This ensures that the output X6/SO will not indicate a HIGH level if a short circuit occurs in the internal transistor and the drive is not switched off via both channels. The switch contacts must resist the maximum current of the 24 V DC voltage supply. All control components (switches, relays, PLC,...) and the control cabinet must comply with the requirements of EN and EN (from : EN ISO 13849). These include among other things: Switches, relays in enclosure IP54. Control cabinet in enclosure IP54. Gather all further requirements from EN and EN (from : EN ISO 13849). The wiring with wire end ferrules is essential. All safety relevant cables (e. g. control cable for the safety relay, feedback contact) must be installed outside the control cabinet, e. g. in the cable duct. It must be ensured that short circuits between the single cables cannot occur. For further measures see EN 954 2, table D4 (of 01/01/2007: EN ISO 13849). 65

66 5 Electrical installation Control terminals Safe torque off "Safe torque off" with safety PLC The version "safe torque off" with safety PLC must ensure the functions of the multiple contact switches. The following conditions must be fulfilled: The NO contacts only close after the NC contacts are open. Voltage supply for the brake must be safely switched off in the event of LOW level at X6/SI1 and/or LOW level at X6/SI2. Voltage supply for the output X6/SO must be safely switched off in the event of HIGH level at X6/SI1 and/or HIGH level at X6/SI2. Safe processing of the output signal at X6/SO for higher level safety concepts. The PLC must be programmed so that the following requirements are met: The input and output states of output X6/SO are checked for plausibility according to the following truth table. The entire system is put into a safe state, when the plausibility check results in an impermissible state. States of the "safe torque off" function on the axis module Level at input terminal Resulting level at Impermissible level at output terminal output terminal X6/SI1 X6/SI2 X6/SO X6/SO LOW LOW HIGH LOW LOW HIGH LOW HIGH LOW LOW HIGH HIGH HIGH LOW All control components (switches relays, PLC,...) and the control cabinet must comply with the requirements of the EN and EN (from : EN ISO 13849). This includes among other things: Switches, relays with enclosure IP54. Control cabinet with enclosure IP54. Gather all further requirements from EN and EN (from : EN ISO 13849). The wiring with wire end ferrules is essential. All safety relevant cables (e. g. control cable for the safety relay, feedback contact) must be installed outside the control cabinet, e. g. in the cable duct. It must be ensured that short circuits between the single cables cannot occur! For further measures see EN (from :13849), table D4. 66

67 Electrical installation Control terminals Safe torque off Function check After installation the operator must check the "safe torque off" function. The function check must be repeated at regular intervals, after one year at the latest. Stop! If the function check leads to impermissible states at the terminals, commissioning cannot take place! Test specifications Check the circuitry with regard to correct function. Check directly at the terminals whether the "safe torque off" function operates faultlessly in the axis module: States of the "safe torque off" function on the axis module Level at input terminal Resulting level at Impermissible level at output terminal output terminal X6/SI1 X6/SI2 X6/SO X6/SO LOW LOW HIGH LOW LOW HIGH LOW HIGH LOW LOW HIGH HIGH HIGH LOW 67

68 5 Electrical installation Control terminals Safe torque off Example: Wiring with electronic safety control unit for category 3 Fig.5 13 Example: Wiring with "Siemens 3TK2842"safety control unit T1 Test key 1 T2 Test key 2 The motor is shutdown in accordance with stop category 1 of EN when the safety function is requested. The delay time of the safety control unit and the quick stop deceleration time have to be coordinated with the brake closing time. ECSXA102 The diode capacitor combination prevents the test pulses of the safety control unit from disturbing the smooth running of the motor, as otherwise a short time inhibit of the controller cannot be ruled out. It can be procured from the company Pilz (Pilz order number: ) as a complete terminal. Manual test of the disconnecting paths The disconnecting paths have to be checked individually in succession. If the test keys (T1, T2) are pressed, the motor has to be torqueless immediately and the brake has to engage. When the safety control unit is switched off, or if both test keys are pressed at the same time, the feedback "STO" has to signalise. This feedback is not reliable and only serves as an information for the operator that a switch on is possible now. If the actual state deviates from the facts described here, switch off the drive immediately. Eliminate the fault before the restart is carried out. 68

69 Electrical installation Automation interface (AIF) Automation interface (AIF) A communication module can be plugged on or removed from the automation interface (X1). This can also be done during operation. Various communication modules are available for supply modules and axis modules of the ECS series: Communication module Keypad XT Card module Diagnosis terminal (Keypad XT with hand held) LECOM A (RS232) LECOM B (RS485) LECOM A/B (RS232/485) LECOM LI (optical fibre) FP interface LON INTERBUS PROFIBUS DP DeviceNet/CANopen CAN addressing Type/order number EMZ9371BC EMZ2221IB E82ZBBXC EMF2102IB V004 EMF2102IB V002 EMF2102IB V001 EMF2102IB V003 EMF2103IB EMF2141IB EMF2113IB EMF2133IB EMF2175IB EMF2174IB Further information... on wiring and application of communication modules can be found in the corresponding Mounting Instructions and Communication Manuals. 69

70 5 Electrical installation Wiring of MotionBus/system bus (CAN) 5.5 Wiring of MotionBus/system bus (CAN) Basic wiring of the CAN buses The two following schematic diagrams show drive systems with different master value concepts: In Fig.5 14 a higher level control takes over the function of the master, e. g. ETC. In Fig.5 15 the function of the master is enabled by a controller that is assigned to the master. In both representations the master value transmission is effected via the MotionBus(CAN). The system bus (CAN) serves to diagnose and/or parameterise the drives. M PC HMI MB SB X4 X14 X4 X14 X4 X14 S S S Fig.5 14 MotionBus (CAN) with higher level control MB MotionBus (CAN), connection to plug connector X4 SB System bus (CAN), connection to plug connector X14 M Master E Slave PC PC HMI HMI / operating unit ECS_COB006 PC HMI MB SB X4 X14 X4 X14 X4 X14 M S S Fig.5 15 MotionBus (CAN) with controller as master MB MotionBus (CAN), connection to plug connector X4 SB System bus (CAN), connection to plug connector X14 M Master E Slave PC PC HMI HMI / operating unit ECS_COB007 70

71 Electrical installation Wiring of MotionBus/system bus (CAN) 5 Fig.5 16 Bus connections on the controller ECS_COB003 Assignment of the plug connectors X4 (CAN) X14 (CAN AUX) Description CH CAH CAN HIGH CL CAL CAN LOW CG CAG Reference potential Specification of the transmission cable For the use of the transmission cable, follow our recommendations: Specification of the transmission cable Total length 300 m 1000 m Cable type LIYCY 2 x 2 x 0.5 mm2 (paired with shielding) CYPIMF 2 x 2 x 0.5 mm 2 (paired with shielding) Cable resistance 80 /km 80 /km Capacitance per unit 130 nf/km 60 nf/km length 71

72 5 Electrical installation Wiring of MotionBus/system bus (CAN) Wiring of the MotionBus(CAN) Fig.5 17 Example of wiring the MotionBus (CAN) ECS ECS axis module M Higher level control, e. g. ETC ECS_COB004 Note! Respectively connect one bus terminating resistor (120 ) to the first and the last node of the MotionBus (CAN) / system bus (CAN). 72

73 Electrical installation Wiring of MotionBus/system bus (CAN) 5 Bus cable length Note! Be absolutely sure to observe the permissible cable lengths. 1. Check the compliance with the total cable length in Tab The total cable length is defined by the baud rate. Baud rate [kbit/s] Tab. 5 1 Total cable length Max. bus length [m] 2. Check the compliance with the segment cable length in Tab The segment cable length is defined by the cable cross section used and by the number of nodes. Without using a repeater, the segment cable length equals the total cable length. Nodes Cable cross section 0.25 mm mm mm mm m 430 m 650 m 940 m m 420 m 640 m 920 m m 410 m 620 m 900 m m 390 m 580 m 850 m m 360 m 550 m 800 m m 310 m 470 m 690 m Tab. 5 2 Segment cable length 3. Compare the two identified values to each other. If the value determined from Tab. 5 2 is smaller than the total cable length from Tab. 5 1 that is to be realised, the use of repeaters is required. Repeaters divide the total cable length into segments. Observe... the information on the use of a repeater in the CAN Communication Manual. 73

74 5 Electrical installation Wiring of the feedback system Resolver connection 5.6 Wiring of the feedback system Different feedback system can be connected to the axis module: Resolver to X7 ( 74) Encoder to X8 ( 75) Incremental encoder with TTL level Sin/cos encoder with rated voltage ( V) Sin/cos absolute value encoder (single turn/multi turn) with serial communication (Hiperface interface) Note! If a "safe isolation" acc. to EN between the encoder cable and motor cable (e.g. by using separating webs or separated draglines) is not ensured on the entire cable length cable due to an installation on the system side, the encoder cable must be provided with an insulation resistance of 300 V. Lenze encoder cables meet this requirement. We recommend to use Lenze encoder cables for wiring. In case of self prepared cables only use cables with shielded cores twisted in pairs. observe the notes on wiring/preparation on the following pages Resolver connection Note! Before using a resolver from another manufacturer, please consult Lenze. Connect a resolver via the 9 pole Sub D socket X7. Features Resolver: U = 10 V, f = 4 khz Resolver and resolver supply cable are monitored for open circuit (fault message "Sd2"). 74

75 Electrical installation Wiring of the feedback system Encoder connection 5 X7 mm 2 AWG +REF -REF X7 +COS KTY -COS +SIN -SIN R1 (+KTY) R2 (-KTY) Fig.5 18 Resolver connection ECSXA022 Assignment of socket connector X7: Sub D 9 pole Pin Signal +Ref Ref GND +COS COS +SIN SIN R1 (+KTY) 0.5 mm 2 (AWG 20) 0.14 mm 2 (AWG 26) R2 ( KTY) Encoder connection Danger! For operating systems up to and including version 7.0: Uncontrolled movements of the drive possible when absolute value encoders are used! If an absolute value encoder is disconnected from the axis module during operation, a OH3 TRIP (fault no. "0053") occurs. If the absolute value encoder now is connected to X8 again and a TRIP RESET is carried out, the drive may start up in an uncontrolled manner with a high speed and a high torque. An SD8 TRIP (fault no. "0088") will not occur, as would be expected. Possible consequences: Death or severest injuries Destruction or damage of the machine/drive Protective measures: If a TRIP occurs during commissioning when an absolute value encoder is used, check the history buffer C0168. If an SD8 TRIP (fault no. "0088") is at the second or third place, it is absolutely necessary to switch off and on again the supply of the control electronics (24 V supply). 75

76 5 Electrical installation Wiring of the feedback system Encoder connection Via the 9 pole Sub D plug X8, you can connect the following encoders: Incremental encoder with two 5 V complementary signals (TTL encoders) that are electrically shifted by 90. Optionally, the zero track can be connected. Sin/cos encoder with rated voltage ( V). with serial communication (single turn or multi turn; the initialisation time of the axis module is extended to approx. 2 s). The controller supplies the encoder with voltage. Use C0421 to set the supply voltage V CC ( V) to compensate, if required, the voltage loss [U] on the encoder cable: U 2 L L [m] Rm[m] I G [A] U L L R/m I G Voltage loss on the encoder cable [V] Cable length [m] Resistance per meter of cable length [/m] Encoder current [A] Stop! Observe the permissible connection voltage of the encoder used. If the values in C0421 are set too high, the encoder can be destroyed! 76

77 Electrical installation Wiring of the feedback system Encoder connection 5 Incremental encoder (TTL encoder) Features Input/output frequency: Current consumption: Current on output V CC (X8/pin 4): khz 6 ma per channel Max. 200 ma <50m B X8 5 9 KTY B A A V CC GND Z Z R1 (+KTY) R2 (-KTY) A A B B Z Z 6 Fig.5 19 Connection of incremental encoder with TTL level Signals in case of clockwise rotation Cores twisted in pairs ECSXA026 Assignment of plug connector X8: Sub D 9 pole Pin Signal B A A V CC GND (R1/+KTY) Z Z R2 ( KTY) B 0.14 mm 2 (AWG 26) 1 mm 2 (AWG 18) 0.14 mm 2 (AWG 26) 77

78 5 Electrical installation Wiring of the feedback system Encoder connection SinCos encoder Features Input/output frequency: Internal resistance (R i ): Offset voltage for signals SIN, COS, Z: khz 221 The differential voltage between signal track and reference track must not exceed 1 V 10 %. 2.5 V The connection is open circuit monitored (fault message "Sd8") For encoders with tracks sine, sine and cosine, cosine: Assign RefSIN with sine. Assign RefCOS with cosine. <50m RefSIN X8 5 9 KTY SIN RefCOS COS V CC GND Z Z R1 (+KTY) R2 (-KTY) SIN RefSIN COS RefCOS 6 0.5V 0.5 V = 2.5 V = 2.5 V Fig.5 20 Sin/cos encoder connection Signals in case of clockwise rotation Cores twisted in pairs ECSXA023 Assignment of plug connector X8: Sub D 9 pole Pin Signal SIN RefCOS (cos) 0.14 mm 2 (AWG 26) COS V CC GND (R2/ KTY) 1 mm 2 (AWG 18) Z or RS458 Z or +RS mm 2 (AWG 26) R1 (+KTY) RefSIN (sin) 78

79 Commissioning Before you start 6 6 Commissioning 6.1 Before you start Note! In the description of the commissioning steps the use of a Lenze motor is assumed. For details on the operation with other motors see 144. The operation with the Lenze parameter setting and operating program Global Drive Control (GDC) is taken as a basis. The parameters are displayed in the online mode, i.e. GDC can directly access the codes of the axis module. Prior to initial switch on of the drive system, check the wiring for completeness, short circuit, and earth fault: Power connection: Polarity of the DC bus voltage supply via terminals +UG, UG Motor connection: Connection to the motor in correct phase relation (direction of rotation) Wiring of safe torque off" (formerly "safe standstill") Feedback system Control terminals: Wiring adjusted to the signal assignment of the control terminals. 79

80 6 Commissioning Commissioning steps (overview) 6.2 Commissioning steps (overview) Start Carry out the basic setting ( 81) Set homing ( 83) Optimise drive behaviour ( 152) Save parameters in the drive with C0003 = 1. Save parameter set with GDC in the parameter set file. End 80

81 Commissioning Commissioning steps (overview) Basic settings with GDC Basic settings with GDC Note! Follow the commissioning steps in the given order! Setting Short description Detailed information Requirements Main is switched off. (Green LED is dark, red LED is blinking) Controller inhibit is active. Press the button <F9> in GDC. X6/SI1 or X6/SI2 must be open (LOW). Control bit 9 = 1 1. Switch on low voltage supply. 2. Connect PC / laptop (with installed GDC parameter setting program) with the controller. 3. Start GDC and select the device to be set. Connection to X14 (system bus (CAN)) with PC system bus adapter EMF2177IB. Selecting a device: Change to the online mode via the GDC tool bar with the <F4> key and select "Searching for drives" using the <F2> key. Drive is identified and the parameter menu is opened. 4. Load Lenze setting. Not required for the first commissioning of the axis module. Only recommended if the Lenze setting is unclear. 5. Set communication CAN node address (via DIP switch or C0350/C2450) parameters. Baud rate (via DIP switch or C0351/C2451) C0356 (CAN boot up/cycle time) C1120 = 1 (sync connection via MotionBus (CAN)) C1121 (synchronisation cycle [in ms]) 159 GDC online help Set mains data. Set the following codes in the GDC parameter menu under 87 Short setup Mains: C0173 (voltage thresholds) C0175 (function of the charge relay) For operation with power supply module ECSxE set C0175 = Enter motor data. Lenze motors: Use the motor assistant of the GDC. 89 Motors of other manufacturers Configure holding brake. Not required if a holding brake is not available; otherwise Set C0472/10 (speed threshold) > 0 (e. g. 1 %) for closing the holding brake Set feedback system. Lenze resolvers do not require further settings. Set other resolvers and encoders in the GDC parameter menu under Motor/Feedback Feedback. 10. Set toggle bit monitoring. Set the following codes in the GDC parameter menu under Monitoring: C3160 (toggle bit error handling) C3161 (toggle bit error counter limit)

82 6 Commissioning Commissioning steps (overview) Basic settings with GDC Setting Short description 11. Enter machine parameters. Set the following codes in the GDC parameter menu under Motion Machine parameter: C0011 (max. speed) C0105 (deceleration time for quick stop (QSP)) C0596 (max. system speed) C3030 (following error warning limit) C3031 (following error limit FAIL QSP) C3032 (1st response when following error limit has been reached) C3033 (2nd response when following error limit has been reached) 12. Switch on the mains. Green LED is blinking and red LED is off: Controller is ready for operation. Green LED is off and red LED is blinking: A fault has occurred! Eliminate the fault before you carry on with commissioning. Detailed information 110 The basic settings are completed now. Proceed with the settings for homing ( 83). 82

83 Commissioning Commissioning steps (overview) Setting of homing Setting of homing Homing By means of homing, the definition of the measuring system in the machine is effected, and therefore also the definition of the zero position within the traversing range that is physically possible Position Fig.6 1 Homing (specification of the zero position) The zero position (home position) can be defined by homing or by setting a reference: During homing the drive traverses in a defined mode (homing mode) to detect the zero position on its own and in a reproducible manner. When homing is carried out, the current position is defined as zero position (home position). The homing setting described in this chapter requires the following system structure: CAN-AUX ECSXA418 X14 X7 X24 X6 ECSxM... DI1 DI2 DI3 DI4 DO1 0 1 Ref TP Z2 R Z1 Fig.6 2 Basic system structure ECSxM... axis module with "Motion" application software Speed / position feedback Motor power connection Change over between reference switch and touch probe sensor (only required in the homing modes 6 and 7! 114) Negative hardware limit switch Reference switch Touch probe sensor Positive hardware limit switch Gearbox with ratio i = Z2/Z1 (ratio of the number of teeth or circumferences) or i = n1/n2 (ratio of speeds) Servo motor ECSXA500 83

84 6 Commissioning Commissioning steps (overview) Setting of homing Setting sequence: Comply with... the safety and application instructions for multi axis applications in the corresponding manuals and on the systems. Note! Follow the commissioning steps in the given order! Setting Short description Detailed information 1. Set homing parameters. Set the following codes in the GDC parameter menu under Motion Homing: 112 C3010 (homing mode) C3011 (zero position offset with drive traversing) C3012 (zero position offset without drive traversing) C0935 (traversing speed of homing) C0936 (deceleration time (T i ) of homing) 2. Save parameter set. Set C0003 = A Select "Homing Mode". The "homing" mode is automatically selected by the master 132 control: C5000 = 6 The operating mode can also be set manually in the GDC parameter menu under Motion Operating mode. B Confirm setting of "Homing Mode". In order that the drive performs homing, the ECSxM axis module must write the value from C5000 into C5001 (here C5001 = 6). If this is not the case, set the operating mode manually (step 3 A). If the value from C5000 has not been written into C5001 after repeating step 3 A), please contact Lenze! 4. Enable controller. The controller can only be enabled via a master control. 139 Green LED is lit continuously if X6/SI1 = HIGH, X6/SI2 = HIGH, and the controller has been enabled via the master control. Green LED is blinking if X6/SI1 = HIGH and X6/SI2 = HIGH. (No enable via master control!) 5. Start homing. The master control set the control bit 12 = 1 (TRUE). 104 Note: In order to interrupt homing, the control bit 12 must be reset to "0" using the master control. The drive approaches the home position according to the setting in C

85 Commissioning Commissioning steps (overview) Setting of homing 6 Setting 6. A Select "Interpolated Position Mode". B Confirm setting of "Interpolated Position Mode". 7. Start travel according to the setpoint selection. Short description The "Interpolated Position Mode" is automatically selected by the master control: C5000 = 7 The operating mode can also be set manually in the GDC parameter menu under Motion Operating mode. In order that the drive performs a travel according to the setpoint selection, the ECSxM axis module must write the value from C5000 into C5001 (here C5001 = 7). If this is not the case, repeat step 6 A. If the setting from C5000 has not been transferred to C5001 after repeating step 6 A, please contact Lenze! The master control sets the control bit 12 = 1 (TRUE). Note: In order to interrupt homing according to the setpoint selection, the control bit 12 must be reset to "0" using the master control. Detailed information The settings for homing are completed now. Now you can optimise the drive behaviour ( 152). 85

86 6 Commissioning Loading the Lenze setting 6.3 Loading the Lenze setting Note! If an axis module with the "Motion" application software is reset to the Lenze setting, previous settings get lost (mains and motor data, feedback system settings, CAN node addresses)! The GDC contains the parameters or codes to be set in the parameter menu under Load / Store: Fig.6 3 GDC view: Parameter set management ECSXA312 Setting sequence: 1. Stop the PLC program: C2108 = 2 2. Load Lenze setting: C0002 = 0 3. Continue with 3.1 or (Switching the 24 V supply voltage is possible): A Switch off and on again 24 V supply voltage. B Plug the keypad XT (EMZ9371BC) onto the AIF interface (X1). 3.2 (Switching the 24 V supply voltage is not possible): A Plug the keypad XT (EMZ9371BC) onto the AIF interface (X1). B Execute PLC Reset: C2108 = 3 4. Parameterise CAN node addresses via C0350 and C2450. ( 185) 5. Continue with basic settings from point 5 of the table on Automatic start of the PLC program after power up: C2104 = 1 7. Start the PLC program: C2108 = 1 8. Save parameter set: C0003 = 1 86

87 Commissioning Setting of mains data Selecting the function of the charging current limitation Setting of mains data The GDC includes the parameters and codes to be set in the parameter menu under Short setup Mains: Fig.6 4 GDC view: Short setup of the mains data ECSXA Selecting the function of the charging current limitation The ECS axis modules are provided with a charging current limitation by means of charge resistors and charge relays. In the Lenze setting the charging current limitation is activated (C0175 = 1). At mains connection the charge relay remains open for a while so that the charging current of the DC bus is limited by the charging resistors. When a certain voltage level has been reached, the charging resistors are short circuited by switching on (closing) the charge relay contacts. Stop! If the DC bus voltage is generated with an ECSxE power supply module, the DC bus is loaded in a controlled way. Therefore, set C0175 = 3 for the axis module. If the Lenze setting has been loaded via C0002, C0175 = 3 must be reset. Cyclic connection and disconnection of the mains voltage of the power supply module can overload and destroy the input current limitation of the axis module if C0175 = 1 or C0175 = 2. For this reason allow a break of three minutes between two starting operations in case of cyclic mains switching over a longer period of time! 87

88 6 Commissioning Setting of mains data Setting the voltage thresholds Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0175 UG Relais Fkt 1 Charge relay behaviour with undervoltage (LU) in the DC bus. 1 Standard Relay switches as a function of LU. 2 One Time Relay switches when LU is exceeded for the first time and remains on. 3 Fixed On Charging current limitation is inactive. Relay is always switched on and the charging resistors of the axis module are thus permanently jumpered. Setting for operation with ECSxE power supply module Setting the voltage thresholds Note! All drive components in DC bus connections must have the same thresholds! Selection Mains voltage Brake unit LU message (Undervoltage) C0173 Power supply module [V AC] Setting [V DC] Resetting [V DC] OU message (Overvoltage) Setting [V DC] Resetting [V DC] yes/no yes/no yes/no no yes yes/no C0174 C V (Lenze setting) yes/no C0174 C V yes/no C0174 C V no C0174 C V yes C0174 C V Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0174 UG min 60 Undervoltage threshold of DC bus (LU) 15 {1 V}

89 Commissioning Entry of motor data for Lenze motors Entry of motor data for Lenze motors Note! The following only describes the parameter setting for Lenze motors! (For operation with motors of other manufacturers see: 144) If the Lenze setting has been loaded via C0002, the motor data must be re entered. Parameter setting with the "Input assistant for motor data" of the GDC 1. Go to the GDC menu bar and select the Tool Motor data menu item or click the button with the voltage divider symbol in the tool bar (rightmost in Fig.6 5): Fig.6 5 GDC view: menu bar and tool bar The "Input assistant for motor data" opens: ECSXA300 Fig.6 6 GDC view: Selection of motor list 2. Select the "Lenze motor list" and click the [ Continue ] button. ECSXA311 89

90 6 Commissioning Entry of motor data for Lenze motors Fig.6 7 GDC view: Motor selection ECSXA Select the connected motor from the list (see motor nameplate). The corresponding motor data is displayed on the right in the "Motor data" fields. 4. Click the [ Complete ] button. The data is transferred to the controller. This process can take a few seconds and is confirmed by a message after being completed. 90

91 Commissioning Holding brake configuration Holding brake configuration Tip! If you use a motor without a holding brake, you can skip this chapter. In the GDC, the parameters or codes to be set can be found in the parameter menu under Short setup Brake. Fig.6 8 GDC view: Short setup of the holding brake ECSXA531 code Designation Description C0195 Brake closing The time required for closing the holding brake. time/activation time Only after this time has elapsed, the controller inhibit is activated (control bit 9 = 1 (TRUE)). C0196 Brake opening The time required for opening the holding brake. time/release time During the time set the drive generates the torque set under C0244 against the holding brake. If an actual speed higher than the value in C0472/10 is detected before the brake opening time (C0196) has expired, the drive can immediately change to speed controlled operation. C0244 Holding torque Holding torque of the drive against the holding brake 100 % value of C0057 C0472/10 FCODE analog [%] Speed threshold for closing the brake: Only if the actual speed value has fallen below the speed threshold, the "close brake" signal is output. This code refers to the maximum speed set in C0011. Note: Enter a value > 0 so that the brake can be opened. C0472/11 FCODE analog [%] Value/direction of the torque against the holding brake. 91

92 6 Commissioning Holding brake configuration Closing the brake Closing the brake CtrlWord.Bit7 QSP t Use control bit 7 = 0 (FALSE) to close the brake. At the same time the internal quick stop (QSP) is activated and the drive is braked to standstill within the deceleration time set in C0105 (NSet = 0). NSet t C0472/10 If the speed falls below the speed threshold in C0472/10, the brake is activated via the digital output X6/B+. X6/B+ CtrlWord.Bit9 C0195 t t After the brake closing time in C0195 has elapsed, the controller inhibit (CINH) is activated (control bit 9 = 1 (TRUE)). t ECSXA518 CtrlWord.Bit7 Controller enable (control bit 7) QSP Quick stop Nset Setpoint speed X6/B+ Digital output X6/B+ CtrlWord.Bit9 Controller inhibit (control bit 9) Brake is open Brake is closed 92

93 Commissioning Holding brake configuration Opening the brake Opening the brake CtrlWord.Bit7 CtrlWord.Bit9 t Use control bit 7 = 1 (TRUE) to enable the controller. The control bit 9 is set to 0 (FALSE) at the same time (controller inhibit (CINH) is deactivated) and the torque defined in C0244 is created. This happens within the brake opening time set in C0196. C0244 t MAct t C0244 As soon as the torque (Mact) has reached the value in C0244, the brake is opened. X6/B+ QSP C0196 t t If the brake is opened via the digital output X6/B+, the following happens after the brake opening time has elapsed (C0196) Quick stop (QSP) is cancelled. Setpoint integrator is enabled. NSet t t ECSXA519 CtrlWord.Bit7 Controller enable (control bit 7) CtrlWord.Bit9 Controller inhibit (control bit 9) Mact Actual torque X6/B+ Digital output X6/B+ QSP Quick stop (QSP) Nset Setpoint speed Brake is closed Brake is open 93

94 6 Commissioning Setting of the feedback system for position and speed control Resolver for position and speed control 6.7 Setting of the feedback system for position and speed control These feedback systems can be set for position and speed control: Resolver at X7 ( 94) Incremental encoder/sincos encoder without serial communication at X8 ( 97) Absolute value encoder (Hiperface, single turn/multi turn) at X8 ( 98) Note! If the Lenze setting has been loaded via C0002, the feedback system must be reset Resolver for position and speed control If a resolver is connected to X7 and used for position and speed control, no settings are required. Lenze setting: Feedback system for position control: C0490 = 0 Feedback system for speed control: C0495 = Codes for setting the resolver feedback The GDC includes the parameters or codes to be set in the parameter menu under Short setup Feedback: Fig.6 9 GDC view: Commissioning of the feedback system ECSXA532 Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection [C0490] Feedback pos 0 Selection of feedback system for positioning control 0 Resolver at X7 Standard setting 1 TTL encoder at X8 Sets C0495 to the same value 2 SinCos encoder at X8 if C0495 > 0. Sets C0419 = 0 ("Common") if 3 Absolute value encoder (single turn) at a different encoder type as X8 under C0419 is set here. 4 Absolute encoder (multi turn) at X

95 Commissioning Setting of the feedback system for position and speed control Codes for setting the resolver feedback 6 Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection [C0495] Feedback n 0 Selection of feedback system for speed control 0 Resolver at X7 Standard setting 1 TTL encoder at X8 Sets C0490 to the same value 2 SinCos encoder at X8 if C0490 > 0. Sets C0419 = 0 ("Common") if 3 Absolute value encoder (single turn) at a different encoder type as X8 under C0419 is set here. 4 Absolute encoder (multi turn) at X8 94 Codes for optimising the operation and display Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0058 Rotor diff 90.0 Rotor displacement angle for synchronous motors (C0095) {0.1 } [C0080] Res pole no. 1 Number of pole pairs of resolver 1 {1} 10 [C0095] Rotor pos adj 0 Activation of rotor position adjustment of a synchronous motor C0058 shows the rotor displacement angle. 0 Inactive 1 Active [C0416] Resolver adj. 5 Resolver excitation amplitude % 1 80 % 2 68 % 3 58 % 4 50 % 5 45 % 6 40 % 7 37 % [C0417] Resolver cor. 0 Resolver adjustment Ready 1 Start adjustment 2 Loading default values 95

96 6 Commissioning Setting of the feedback system for position and speed control Resolver as absolute value encoder Resolver as absolute value encoder If the following requirements are met, a resolver (or single turn absolute value encoder) can take over the function of a multi turn absolute value encoder: When the axis module is switched off, the reference is known. It is ensured that the position of the machine part does not change (e.g. by using a brake) until the axis module is switched on again. C3002 = 1 (no change in position during "POWER OFF") At switch off, the actual position is saved fail safe. After switch on, the actual position is re initialised with this value. Turning the drive by maximally ± ½ revolution of the position encoder when the axis module is switched off will be detected and considered when the actual position is initialised (loaded). General formula for the calculation of the maximum encoder rotation when the axis module is switched off, in particular for multi pole resolvers (number of pole pairs > 1): Max.rotation 180 Numberofpolepairs Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C3002 NoChangeOfP os 0 Resolver as absolute value encoder 0 ChangeOfPos After "mains off/on", homing has to be carried out. The actual position is initialised with the value "0". 1 NoChangeOfPos The actual position value is initialised with the position value at "Mains off" and is used further at "Mains on". Homing is not required. Note: With "Mains off" the feedback system must rotate less than 0.5 revolutions

97 Commissioning Setting of the feedback system for position and speed control Incremental encoder / sin/cos encoder without serial communication Incremental encoder / sin/cos encoder without serial communication If an incremental encoder or a sin/cos encoder without serial communication is connected to X8 and used for position and speed control, comply with the following setting sequence: 1. Select encoder for position and speed control. Incremental encoder (TTL encoder): C0490 and C0495 = 1 Sin/cos encoder without serial communication: C0490 and C0495 = 2 If X8 has been selected as output due to a change of C0491, an automatic reset to input is made due to the encoder selection. 2. Select encoder used. Incremental encoder (TTL encoder): C0419 = Sin/cos encoder without serial communication: C0419 = Encoder used is not in the list: C0419 = 1 ("Common") 3. When setting C0419 = 1 ("Common") configure encoder data. Note! When setting C0419 = 11x or 21x do not configure encoder data. The encoder data (C0420, C0421, C0427) are set automatically in accordance with the selection. C0420 (number of increments of the encoder) C0421 (encoder voltage) C0427 (signal type of the encoder) 4. Set encoder mounting position. C3001 = 0: normal (direction of rotation CW with regard to direction of rotation of the motor) C3001 = 1: inverse (direction of rotation CCW with regard to direction of rotation of the motor) 5. Save settings with C0003 = 1. 97

98 6 Commissioning Setting of the feedback system for position and speed control Absolute value encoder (Hiperface, single turn/multi turn) Absolute value encoder (Hiperface, single turn/multi turn) Danger! For operating systems up to and including version 7.0: Uncontrolled movements of the drive possible when absolute value encoders are used! If an absolute value encoder is disconnected from the axis module during operation, a OH3 TRIP (fault no. "0053") occurs. If the absolute value encoder now is connected to X8 again and a TRIP RESET is carried out, the drive may start up in an uncontrolled manner with a high speed and a high torque. An SD8 TRIP (fault no. "0088") will not occur, as would be expected. Possible consequences: Death or severest injuries Destruction or damage of the machine/drive Protective measures: If a TRIP occurs during commissioning when an absolute value encoder is used, check the history buffer C0168. If an SD8 TRIP (fault no. "0088") is at the second or third place, it is absolutely necessary to switch off and on again the supply of the control electronics (24 V supply). 98

99 Commissioning Setting of the feedback system for position and speed control Absolute value encoder (Hiperface, single turn/multi turn) 6 If an absolute value encoder with a Hiperface interface is connected to X8 and is used for position and speed control, comply with the following setting sequence: 1. Select absolute value encoder for position and speed control. Single turn encoder: C0490 and C0495 = 3 Multi turn encoder: C0490 and C0495 = 4 If X8 has been selected as output due to a change of C0491, an automatic reset of X8 as an input is effected due to the encoder selection. 2. Select an absolute value encoder. Single turn encoder: C0419 = Multi turn encoder: C0419 = The encoder data (C0420, C0421, C0427) is set automatically in accordance with the selection. Danger! Uncontrolled movements of the drive possible when absolute value encoders are used! In the case of an operating system up to and including version 6.7, the drive may start up in an uncontrolled manner with high speed and torque after mains connection and controller enable. Possible consequences: Death or severest injuries Destruction or damage of the machine/drive Protective measures: Do not parameterise codes C0420, C0421 and C0427! 3. Set the encoder mounting position. C3001 = 0: normal (same direction of rotation as direction of rotation of motor) C3001 = 1: inverse (opposite direction of rotation to direction of rotation of motor) 4. Save settings with C0003 = 1. 99

100 6 Commissioning Setting of the feedback system for position and speed control Codes for setting the encoder feedback Codes for setting the encoder feedback The GDC contains the parameters or codes to be set in the parameter menu under Motor/Feedback Feedback. Fig.6 10 GDC view: Commissioning of further feedback systems ECSXA533 Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0058 Rotor diff 90.0 Rotor displacement angle for synchronous motors (C0095) {0.1 } [C0095] Rotor pos adj 0 Activation of rotor position adjustment of a synchronous motor C0058 shows the rotor displacement angle. 0 Inactive 1 Active

101 Commissioning Setting of the feedback system for position and speed control Codes for setting the encoder feedback 6 Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection [C0419] Enc. Setup 110 Encoder selection Selection of encoder type indicated on the nameplate of the Lenze motor. The encoder data (C0420, C0421, C0427) is set automatically in accordance with the selection. 0 Common 110 IT512 5V Incremental encoder with TTL 111 IT1024 5V level 112 IT2048 5V 113 IT4096 5V 210 IS512 5V SinCos encoder 211 IS1024 5V 212 IS2048 5V 213 IS4096 5V 307 AS64 8V SinCos absolute value encoder 308 AS128 8V with Hiperface interface (single turn) 309 AS256 8V Selections 307, 308, 309 are only 310 AS512 8V possible with operating system 7.0 or higher. 311 AS1024 8V 407 AM64 8V SinCos absolute value encoder 408 AM128 8V with Hiperface interface (multi turn) 409 AM256 8V Selections 407, 408, 409 are only 410 AM512 8V possible with operating system 7.0 or higher. 411 AM1024 8V [C0420] Encoder const. 512 Number of increments of the encoder {1 inc/rev} 8192 Sets C0419 = 0 ("Common") if the value is changed. [C0421] Encoder volt 0 Encoder voltage V Sets C0419 = 0 ("common") if the V value is altered V V V V [C0427] Enc. signal 0 Function of the master frequency input signals on X8 (DFIN) 0 2 phase 1 A: speed B: direction 2 A or B: speed or direction

102 6 Commissioning Setting of the feedback system for position and speed control Codes for setting the encoder feedback Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection [C0490] Feedback pos 0 Selection of feedback system for positioning control 94 0 Resolver at X7 Standard setting 1 TTL encoder at X8 Sets C0495 to the same value 2 SinCos encoder at X8 if C0495 > 0. Sets C0419 = 0 ("Common") if 3 Absolute value encoder (single turn) at a different encoder type as X8 under C0419 is set here. 4 Absolute encoder (multi turn) at X8 [C0491] X8 in/out 0 Function of X X8 is input 98 1 X8 is output [C0495] Feedback n 0 Selection of feedback system for speed control 94 0 Resolver at X7 Standard setting 1 TTL encoder at X8 Sets C0490 to the same value 2 SinCos encoder at X8 if C0490 > 0. Sets C0419 = 0 ("Common") if 3 Absolute value encoder (single turn) at a different encoder type as X8 under C0419 is set here. 4 Absolute encoder (multi turn) at X8 C3001 EncDirInv 0 Encoder mounting position 97 0 Normal (direction of rotation CW) Direction of rotation with regard 98 1 Inverse (direction of rotation CCW) to motor direction of rotation 102

103 Commissioning Configuration of control interface (control and status word) Configuration of control interface (control and status word) The communication between control and drive system via fieldbus serves as synchronisation of the control clock rate to the control master master value transfer drive control diagnostics The node address and baud rate are set via: C0350/C0351 (MotionBus (CAN) at X4) alternatively via DIP switch on the device or AIF module C2450/C2451 (system bus (CAN) at X14) C0009 (LECOM) Note! Only the process data channels CAN1_IN and CAN1_OUT of the MotionBus interface X4 are used for communication. The system bus interface X14 can only be used for parameter setting and diagnostics with the Lenze parameter setting and operating program "Global Drive Control" (GDC). The process data channel CANaux2_OUT is used to output the data for commissioning and diagnosing via GDC. Further information on communication can be found in chapter "8 Configuration" ( 166). 103

104 6 Commissioning Configuration of control interface (control and status word) Process data to the axis module Process data to the axis module The process data is transmitted to the axis module via the process data channel CAN1_IN of the MotionBus interface X4. Structure of the transmitted process data User data Word 1 Word 2 DWord (word 3 + word 4) LOW byte HIGH byte LOW byte HIGH byte LOW word HIGH word Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 Application control word (C3152, C3153) Reserved Set position The GDC parameter menu includes codes for displaying the control word (C3152 and C3153) under Motion Status/Control word. Fig.6 11 GDC view: Display of the control word ECSXA

105 Commissioning Configuration of control interface (control and status word) Process data to the axis module 6 Control word The control word (C3152, C3153) consists of 16 bits, each of them giving the following information: Bit Name Level Meaning 0 Toggle HIGH active Toggle bit: The control changes the status of this bit with each telegram. The cyclic "toggling" is monitored in the controller. If the error counter exceeds the value in C3161, the drive reacts according to the function set in C Release limit switch Hardware limit switch monitoring: 0 = limit switch monitoring is active 1 = limit switch monitoring is not active: After a TRIP RESET, the activated hardware limit switch can be retracted. 2 Reserved Reserved 3 QSP Quick stop (QSP): 0 = QSP not active 1 = QSP active: The drive is decelerated to standstill within the deceleration time set in C Monitor data Selection of data required for control. ( 106) 5 selection 6 7 Controller enable Controller enable: 0 = controller not enabled 1 = controller enabled Note: This bit must be set to "1" (TRUE) in order that the controller can operate. 8 Disable Operation inhibit (DISABLE): 0 = operation inhibit not active 1 = operation inhibit active: The drive cannot be started by the command "Controller enable". The power output stages are inhibited. All controllers are reset. 9 CINH Controller inhibit (CINH): 0 = controller inhibit not active 1 = controller inhibit active: The power output stages are only inhibited if the holding brake is activated. All internal controllers are reset. 10 TRIP set Set error (TRIP SET): 0 = no error setting 1 = error setting: The drive is controlled into the status selected under C0581 and signals "EEr" (external monitoring). 11 TRIP RESET Positive edge Reset error (TRIP RESET): 0 = no error resetting 1 = error resetting: This function resets an active TRIP provided that the cause of malfunction has been eliminated. If the cause of malfunction is still active, there will be no reaction. 12 Operation mode specific (1) HIGH active See operating modes: 13 Operation mode specific (2) "Velocity Mode" ( 130) 14 Operation mode specific (3) 15 Reserved HIGH active Reserved "Homing Mode" ( 132) "IP Mode" ( 134) "Manual Jog" ( 137) 105

106 6 Commissioning Configuration of control interface (control and status word) Process data from the axis module Monitor data selection (C3181) Depending on the values of the control bits , the following monitor data can be transmitted from the drive: Value of the control bits Free Monitor data (CAN1_OUT) Meaning 1 MCTRL_nPos_a Axis position 16 bits 2 DINT_TO_INT (MCTRL_dnPosSet_p) Following error (2 15 increments) 3 MCTRL_nNAct_a Current speed (n max = 2 14 increments) 4 MCTRL_nMAct_a Current torque (M max = 2 14 increments) 5 MCTRL_nlAct_a Current motor current (I max = 2 14 increments) 6 MCTRL_nDCVolt_a Current DC bus voltage (2 14 [units] = 1000 V) 7 nposlatchdiff Difference between actual position and actual position at touch probe (C6000) Process data from the axis module The process data from the axis module are transmitted to the MotionBus (CAN) via the process data channel CAN1_OUT of the interface X4. Structure of the transmitted process data User data Word 1 Word 2 DWord (word 3 + word 4) LOW byte HIGH byte LOW byte HIGH byte LOW word HIGH word Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 Application status word (C3150, 3151) Monitor data (C3181) Actual position (2 16 = 1 position encoder revolution) The GDC parameter menu includes the codes for displaying the status word (C3150 and C3151) under Motion Status/Control word. Fig.6 12 GDC view: Display of the status word ECSXA

107 Commissioning Configuration of control interface (control and status word) Process data from the axis module 6 Status word The status word (C3150, C3151) consists of 16 bits each of them giving the following information: Bit Name Level Meaning "Homing mode" operation ( 132) "IP mode"operation ( 134) 0 Toggle HIGH active Toggle bit: The control changes the status of this bit with each telegram. The cyclic "toggling" is monitored in the controller. If the error counter exceeds the value in C3161, the drive reacts according to the function set in C Operation mode specific (1) Homing is active IP mode is active 2 Operation mode specific (2) Reference known 3 Operation mode Reference error specific (3) 4 Operation mode Reference switch specific (4) 5 Axis limit switch LOW active (positive) 6 Axis limit switch (negative) 7 Reserved HIGH active Reserved 8 Status information 0 9 Status information 1 10 Status information 2 11 Status information 3 Evaluation of the position detection (Pos_Latch) Pos_Latch error Touch probe sensor Hardware limit switch of the positive traversing range is activated. Hardware limit switch of the negative traversing range is activated. The following possible values are binary coded. 0: Initialisation after connecting the supply voltage 1: Switch on inhibit (LOCK MODE), restart protection is active (C0142) 3: Controller inhibit (CINH) is active 6: Controller enabled 7: Response of monitoring caused a "message". 8: Response of monitoring caused a "TRIP". 10: Response of monitoring or external quick stop (QSP) via digital input X6/DI1 caused a "FAIL QSP". 12 Warning 1 = Warning (Only display of the failure, the drive continues to run normally.) 13 ActPositionOK 0 = The actual position is not valid anymore. Encoder error: Referencing must be repeated. 14 FailToAckn 1 = An error must be reset. 15 rdy 1 = Ready for operation 107

108 6 Commissioning Configuration of control interface (control and status word) Toggle bit monitoring Toggle bit monitoring Steuerung Motion Toggle-Bit Generator Reglerfreigabe CAN Drive IN OUT Toggle-Bit Unterbrechung bei fehlender Reglerfreigabe Unterbrechung bei fehlender Reglerfreigabe Unterbrechung bei fehlender Reglerfreigabe CAN-PDO CAN-PDO CAN-PDO IN OUT IN OUT IN OUT Toggle-Bit Monitoring Toggle-Bit Monitoring Toggle-Bit Monitoring Error handling Error handling Error handling Antriebsregler 1 Antriebsregler 2 Antriebsregler n Fig.6 13 Basic principle of toggle bit monitoring ECSXA501 The toggle bit monitoring serves to control the sync controlled transmission of telegrams on the CAN bus. In the "Motion" application a bit pattern is generated in the control which changes between the HIGH and LOW states. This bit pattern is cyclically transmitted to the next controller in the drive system via a process data channel of the MotionBus (CAN). Each controller monitors the status change of the toggle bit and simultaneously gives the bit pattern 1:1 back to the control. If errors occur in the drive system, they are evaluated independently in each controller involved. In the event of an error (e. g. if a telegram is not transmitted) the toggle bit error counter is increased by 1. Depending on error limit (C3161) and error handling (3160) all controllers involved can react independently of the communication (error handling). 108

109 Commissioning Configuration of control interface (control and status word) Toggle bit monitoring 6 In the GDC, the error limit (C3161) and error handling (C3160) can be set in the parameter menu under Monitoring. Fig.6 14 GDC view: Monitoring ECSXA545 Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C3160 ToggleErrReac 3 Toggle bit error handling TRIP 1 Message 2 Warning 3 Off 4 FAIL QSP C3161 ToggleErLimit 4 Toggle bit error counter limit {1 units}

110 6 Commissioning Entry of machine parameters 6.9 Entry of machine parameters The GDC parameter menu includes the codes for machine parameters (e.g. deceleration time for quick stop or maximum speeds) under Motion Machine parameter. Fig.6 15 GDC view: Short setup, entry of machine parameters ECSXA535 Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0011 Nmax 3000 Maximum speed 500 {1 rpm} Reference value for the absolute and relative setpoint selection for the acceleration and deceleration times. For parameter setting via interface: greater changes in one step should only be made when the controller is inhibited (CINH)! C0105 QSP Tif 0.0 Deceleration time for quick stop (QSP) {0.001 s} Relating to speed variation n max (C0011)...0 rev./min. C0596 NMAX limit 5500 Monitoring: Maximum speed of the machine 0 {1 rpm} C3030 FolloErrWarn Following error limit for enabling a warning 0 {1 inc} C3031 FolloErrFail Following error limit for enabling a FAIL QSP (Quick stop (QSP) is executed.) 0 {1 inc} C3032 FollErr1reac 2 First reaction when following error limit has been reached 0 TRIP 1 Message 2 Warning 3 Off 4 FAIL QSP

111 Commissioning Entry of machine parameters 6 Code No. Designation Possible settings Lenze/ {Appl.} Selection IMPORTANT C3033 FollErr2reac 4 Second reaction when following error limit has been reached 0 TRIP 1 Message 2 Warning 3 Off 4 FAIL QSP

112 6 Commissioning Setting of homing parameters Homing parameters 6.10 Setting of homing parameters During homing the drive traverses in a preselected mode (C3010). While doing so, the zero position (reference) is detected by means of a reference mark and transmitted to the drive control. All position data refer to this reference. The GDC parameter menu includes the codes for setting the homing parameters (e.g. homing mode, speed, offsets) under Motion Homing. Fig.6 16 GDC view: Short setup, entry of homing parameters ECSXA Homing parameters Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0935 L_REF1 speed 100 Traversing speed of homing {1 rpm} C0936 L_REF1 Ti 1,0 Deceleration time (T i ) of homing 112 0,01 {0,01 s} 650,00 C3008 HomeMlim 10,0 Torque limit value for homing mode C3010 = 16 or 17 (100,00 % = maximum torque from C0057) C3009 TimeHomeMli m 0,00 {0,01 %} 100, Duration for detecting the mechanical limit stop for homing mode C3010 = 16 or 17 0 {1 ms}

113 Commissioning Setting of homing parameters Homing parameters 6 Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C3010 HomingMode 8 Homing mode >_Rn_MP Selection symbolism: <_Rn_MP >: Movement in pos. direction <: Movement in neg. direction 2 >_Lp_<_Rn_MP Lp: Limit switch in pos. direction 3 <_Ln_>_Rn_MP Ln: Limit switch in neg. direction 4 >_Rp_<_Rn_MP Rp: Pos. edge of the reference switch 5 <_Rp_>_Rn_MP Rn: Neg. edge of the reference switch 6 >_Rn_>_TP MP: Zero pulse/position of 7 <_Rn_<_TP the position encoder, once per motor revolution 8 >_TP TP: Touch probe signal Mlim: mechanical limit stop 9 <_TP (torque limit value) 10 >_Lp_<_TP Notes: When using the homing 11 <_Ln_>_TP modes , set C0540 = 2. The mechanical limit stop is 12 >_Lp_<_MP defined as exceedance of the torque limit C3008 for the 13 <_Ln_>_MP duration C3009. When the last action listed is 14 >_MP executed, the home position 15 <_MP is set (e.g. zero pulse with "MP"), even if the drive continues traversing. 16 >_MLim In all modes without limit 17 <_MLim switch ("Lp" / "Ln") retracting from the limit switch with 99 Set reference error handling set in C317 is not possible. C3011 Home offset 0 Offset between home position and standstill position {1 inc} C3012 Measure offs. 0 Offset for shifting the zero position with regard to the standstill position {1 inc}

114 6 Commissioning Setting of homing parameters Homing modes Homing modes Modes 0 and 1 Travelling to zero pulse (zero position of the position encoder) via the reference switch. Ref R Fig.6 17 Homing in mode 0 Negative hardware limit switch Reference switch Zero pulse (zero position of the position encoder) Positive hardware limit switch Load (e.g. slide) Direction of travel Home position ECSXA510 The load (e. g. slide) travels from its starting position beyond the reference switch to the first zero pulse after leaving the reference switch. This zero pulse bears the home position. Before homing, the load may be positioned on the reference switch. Settings Mode 0 (Homing towards the positive hardware limit switch) Set C3010 = 0. Set C0540 = 2. Mode 1 (Homing towards the negative hardware limit switch) Set C3010 = 1. Set C0540 = 2. Note! Single turn absolute value encoders (sin/cos encoders) and resolvers do not have a zero pulse. Here, the zero position corresponds to the zero pulse In case of multi turn absolute value encoders, only the homing modes and 99 can be used (C3010 = or 99). 114

115 Commissioning Setting of homing parameters Homing modes 6 Modes 2 and 3 Approaching the hardware limit switch, reversing the direction of travel and travelling to the zero position (zero position of the position encoder) via the reference switch. Note! While reversing, the hardware limit switch approached must be assigned (mechanics must be designed accordingly). In a 6 ms cycle, the negative/positive hardware limit switches are queried. Ref R Fig.6 18 Homing in mode 2 Negative hardware limit switch Zero pulse (zero position of the position encoder) Reference switch Positive hardware limit switch Load (e.g. slide) Direction of travel Home position ECSXA511 The load (e.g. slide) from its initial position is traversed to a hardware limit switch. During this process, no fault message is actuated. According to the direction of travel, a reversal takes place at the hardware limit switch approached, and the load, after leaving the reference switch, is traversed to the first zero pulse beyond the reference switch. This zero pulse bears the home position. If the drive has already approached a hardware limit switch before homing, the direction of travel is reversed immediately. In homing modes 2 and 3, the reference switch is definitely found, since, in the most unfavourable case, the entire travel range is covered. Settings Mode 2 (Homing towards the positive hardware limit switch) Set C3010 = 2. Set C0540 = 2. Mode 3 (Homing towards the negative hardware limit switch) Set C3010 = 3. Set C0540 = 2. Note! Single turn absolute value encoders (sin/cos encoders) and resolvers do not have a zero pulse. Here, the zero position corresponds to the zero pulse In the case of multi turn absolute value encoders, only homing modes and 99 can be used (C3010 = or 99). 115

116 6 Commissioning Setting of homing parameters Homing modes Modes 4 and 5 Approaching the reference switch, reversing, and travelling to the zero pulse (zero position of the position encoder). Ref R Fig.6 19 Homing in mode 4 Negative hardware limit switch Zero pulse (zero position of the position encoder) Reference switch Positive hardware limit switch Load (e.g. slide) Direction of travel Home position ECSXA512 The load (e.g. slide) travels from its original position to the reference switch. At the approached reference switch the direction of travel is reversed and the load travels to the first zero pulse after leaving the reference switch. The zero pulse bears the home position. If the drive is already situated at the reference switch, the direction of travel is reversed immediately. Settings Mode 4 (Homing towards the positive hardware limit switch) Set C3010 = 4. Set C0540 = 2. Mode 5 (Homing towards the negative hardware limit switch) Set C3010 = 5. Set C0540 = 2. Note! Single turn absolute value encoders (sin/cos encoders) and resolvers do not have a zero pulse. Here, the zero position corresponds to the zero pulse In case of multi turn absolute value encoders, only the homing modes and 99 can be used (C3010 = or 99). 116

117 Commissioning Setting of homing parameters Homing modes 6 Mode 6 and 7 Travelling to touch probe signal via reference switch. X6/DI2 0 1 Ref TP X6/DO1 R Fig.6 20 Homing in mode 6 Negative hardware limit switch Reference switch Touch probe signal (touch probe sensor) Positive hardware limit switch Load (e.g. slide) Direction of travel Home position ECSXA513 The touch probe is used if the zero pulse (zero position of the position encoder) does not occur reproducibly at the same position due to the mechanical structure. It is also possible that the zero pulse is mechanically shifted after a motor replacement. The load (e.g. slide) travels from its original position beyond the reference switch to the first touch probe signal after leaving the reference switch. This touch probe signal bears the home position. A HIGH level is pending at the digital input X6/DI2. Before homing, the load may already be situated on the reference switch. Use X6/DO1 to switch a relay which changes over between reference switch and touch probe sensor at X6/DI2. ( 58) Settings Mode 6 (Homing towards the positive hardware limit switch) Set C3010 = 6. Set C3010 = 7. Mode 7 (Homing towards the negative hardware limit switch) 117

118 6 Commissioning Setting of homing parameters Homing modes Modes 8 and 9 Travelling to touch probe signal. TP R Fig.6 21 Homing in mode 8 Negative hardware limit switch Touch probe signal (touch probe sensor) Positive hardware limit switch Load (e.g. slide) Direction of travel Home position ECSXA514 The touch probe is used if the zero pulse (zero position of the position encoder) does not occur reproducibly at the same position due to the mechanical structure. It is also possible that the zero pulse is mechanically shifted after a motor replacement. The load (e.g. slide) travels from its original position to the first touch probe signal which lies in the direction of travel. This touch probe signal bears the home position. Settings Mode 8 (Homing towards the positive hardware limit switch) Set C3010 = 2. If the touch probe signal is already applied to X6/DI2, first of all retracting towards the positive hardware limit switch is performed. Mode 9 (Homing towards the negative hardware limit switch) Set C3010 = 3. If the touch probe signal is already applied to X6/DI2, first of all retracting towards the negative hardware limit switch is performed. 118

119 Commissioning Setting of homing parameters Homing modes 6 Modes 10 and 11 Approaching the hardware limit switch, reversing and travelling towards touch probe signal. Note! While reversing, the hardware limit switch approached must be assigned (mechanics must be designed accordingly). In a 6 ms cycle, the negative/positive hardware limit switches are queried. TP R Fig.6 22 Homing in mode 10 Negative hardware limit switch Touch probe signal (touch probe sensor) Positive hardware limit switch Load (e.g. slide) Home position Direction of travel ECSXA515 The touch probe is used if the zero pulse (zero position) of the position encoder occurs non reproducibly at the same position due to the mechanical structure. It is also possible that the zero pulse is mechanically shifted after a motor exchange. The load (e. g. slide) from its initial position is traversed to a hardware limit switch. During this process, no fault message is actuated. According to the direction of travel, a reversal takes place at the hardware limit switch approached, and the load is traversed to the touch probe signal. This touch probe signal bears the home position. If the drive already is at the hardware limit switch before homing, the direction of travel is reversed immediately. Settings Mode 10 (Homing towards the positive hardware limit switch) Set C3010 = 10. Set C3010 = 11. Mode 11 (Homing towards the negative hardware limit switch) 119

120 6 Commissioning Setting of homing parameters Homing modes Modes 12 and 13 Approaching the hardware limit switch, reversing and travelling to the zero pulse (zero position of the position encoder). Note! While reversing, the hardware limit switch approached must be assigned (mechanics must be designed accordingly). In a 6 ms cycle, the negative/positive hardware limit switches are queried. R Fig.6 23 Homing in mode 12 Negative hardware limit switch Zero pulse (zero position of the position encoder) Positive hardware limit switch Load (e.g. slide) Home position Direction of travel ECSXA516 Zero pulse and hardware limit switch are used if a reference switch and touch probe sensor are not available (e.g. in the case of rotary tables). The load (e.g. slide) from its initial position is traversed to a hardware limit switch. During this process, no fault message is actuated. According to the direction of travel, a reversal takes place at the hardware limit switch approached, and the load travels to the first zero pulse (zero position of the position encoder) after leaving the limit switch. This zero pulse bears the home position. If the drive has already approached the hardware limit switch before homing, the direction of travel is reversed immediately. Settings Mode 12 (Homing towards the positive hardware limit switch) Set C3010 = 12. Set C3010 = 13. Mode 13 (Homing towards the negative hardware limit switch) Note! Single turn absolute value encoders (sin/cos encoders) and resolvers do not have a zero pulse. Here, the zero position corresponds to the zero pulse In the case of multi turn absolute value encoders, only homing modes and 99 can be used (C3010 = or 99). 120

121 Commissioning Setting of homing parameters Homing modes 6 Modes 14 and 15 Travelling to zero pulse (zero position of the position encoder). R Fig.6 24 Homing in mode 14 Negative hardware limit switch Zero pulse (zero position of the position encoder) Positive hardware limit switch Load (e.g. slide) Direction of travel Home position ECSXA517 The zero pulse is only used if a reference switch and touch probe sensor are not available (e.g. in case of rotary tables). The load (e.g. slide) travels from its original position to the first zero pulse which lies in the direction of travel (zero position of the position encoder). This zero pulse bears the home position. Settings Mode 14 (Homing towards the positive hardware limit switch) Set C3010 = 14. Set C3010 = 15. Mode 15 (Homing towards the negative hardware limit switch) Note! Single turn absolute value encoders (sin/cos encoders) and resolvers do not have a zero pulse. Here, the zero position corresponds to the zero pulse In case of multi turn absolute value encoders, only the homing modes and 99 can be used (C3010 = or 99). 121

122 6 Commissioning Setting of homing parameters Homing modes Modes 16 and 17 Approaching the mechanical limit stop and setting home position. R Fig.6 25 Homing in mode 16 Mechanical limit stop (negative) Load (e.g. slide) Mechanical limit stop (positive) Direction of travel Home position ECSXA521 The load (e.g. slide) is travelled from its original position in positive or negative direction towards the mechanical limit stop. The motor torque is limited during homing to the torque limit value (C3008). If the motor torque reaches the torque limit value for a longer time than specified in C3009, the internal speed setpoint is travelled to "0" within the deceleration time set (C0936). After that it is traversed by the offset set in C3011 ( 124). If the internal speed setpoint = 0, a home position is set at this position. v C3009 M C %Mmax C3008 t t g_boperationmodebit2_sw2 1 Fig.6 26 Sequence of homing in mode 16/17 Actual speed value Speed setpoint Mechanical limit stop Actual torque Settings t ECSXM005 Mode 16 (Homing towards the positive mechanical limit stop) Set C3010 = 16. Set C3010 = 17. Mode 17 (Homing towards the negative mechanical limit stop) 122

123 Commissioning Setting of homing parameters Homing modes 6 Mode 99 Set reference R Fig.6 27 Set reference in the mode 99 Negative hardware limit switch Positive hardware limit switch Load (e.g. slide) Home position Use "Set reference" if you want to determine the zero position yourself. no touch probe sensor is available (e.g. in case of rotary tables). ECSXA522 a home position cannot be determined depending on sensors, switches, or zero pulses (e.g. in case of transformed axes). The load (e.g. slide) is situated on a position. Here, it is switched to the homing mode and the reference is set to C C3012 ( 124). The axis does not move. After an internal calculation "Reference OK" is displayed. Note! In case of absolute value encoders (single turn, multi turn), "Set reference" is only possible via C0098 (position offset) in combination with the controller inhibit (CINH). 123

124 6 Commissioning Setting of homing parameters Shifting of the zero position (offset selection) Shifting of the zero position (offset selection) v [m/s] t [s] 0 Ref Fig.6 28 C3012 C3011 Shifting of the zero position Negative hardware limit switch Positive hardware limit switch Home position (zero pulse (zero position of position encoder)) Standstill position after completion of homing Zero position of measuring system after shift by C3012 REF Reference switch ECSXA526 code C3011 C3012 Description Offset between home position and standstill position Distance still to be traversed [inc] after reaching the home position (e.g. zero pulse (zero position of the position encoder)). Positive values: Drive motion towards the positive hardware limit switch. Negative values: Drive motion towards the negative hardware limit switch. Value range: [inc] Offset for shifting the zero position: Positive values: Offset of the zero position towards the negative hardware limit switch. Negative values: Offset of the zero position towards the positive hardware limit switch. The zero position is offset without any further drive motion. Actual position via MotionBus (CAN) = C C3012 (the outcome of this is the offset of the zero position.) Value range: [inc] Example 1. C3011 = [inc]: After reaching the home position (e.g. zero pulse (zero position of the position encoder)) the drive travels in positive direction by [inc]. The zero position is situated at the home position. 2. a) C3012 = [inc] (compare Fig.6 28): The zero position is offset by [inc] in negative direction. Actual position = [inc] [inc] = [inc] b) C3012 = [inc]: The zero position is offset by [inc] in positive direction. Actual position = [inc] + ( [inc]) = [inc] 124

125 Commissioning Setting of homing parameters Example: Reference search with linear positioning axis Example: Reference search with linear positioning axis Settings for homing mode 13 Set homing mode 13 with C3010 = 13. The negative hardware limit switch is to be used as reference switch at the same time: Connect hardware limit switch in parallel with X6/DI3 and X6/DI4. (For terminal assignment see 58) Set C0114/3 and C0114/4 = 1 (LOW level is active). Set travelling speed with C0935. Set acceleration/deceleration with C0936. Define target position as offset to the home position via C3011. C3011 Fig Homing in mode 3, negative hardware limit switch as reference switch Negative hardware limit switch Travel towards reference switch Travel via the defined offset (C3011) towards target position Positive hardware limit switch Zero pulse (zero position of the position encoder) Target position ECSXA

126 6 Commissioning Setting of homing parameters Example: Reference search with linear positioning axis Functional sequence 1. The "Homing" operating mode is selected via SDO ( 176) with C5000 and confirmed with C Homing is started by activating the control bit 12. Control bit 12 = 1 (TRUE) 3. During the homing process the status bit 1 is active. Status bit 1 = 1 (TRUE) 4. The drive travels towards the negative hardware limit switch () and reverses. Since the limit switch is also used as reference switch, the preliminary stop will be set when the drive leaves the limit switch, i.e. when the next zero pulse () of the position encoder is reached, the drive control will know the home position. 5. The drive continues traversing without interruption to the target position () which has been defined as offset to the home position under C When the target position is reached, homing is completed. Control bit 12 = 0 (FALSE) Status bit 2 = 1 (TRUE) 7. The zero position (C3012 plus the distance covered in C3011) is transmitted as actual position to the master control. 126

127 Commissioning Setting of homing parameters Example: Reference search with continuous positioning axis Example: Reference search with continuous positioning axis For applications with an unlimited traversing range (e. g. conveying belts and rotary tables) the reference is always searched via a mark. In that case, the reference switch serves as a mark sensor. Settings for homing mode 8 Set homing mode 8 with C3010 = 8. Set target position as the offset to the home position (TP) via C3011 and C3012. Set travelling speed via C0935. Set acceleration/deceleration via C0936. TP C3011 Fig.6 30 Homing in mode ECSXA520 Travel towards home position Travel via the defined offset towards target position Touch probe sensor (home position) Zero position Target position 127

128 6 Commissioning Setting of homing parameters Example: Reference search with continuous positioning axis Functional sequence 1. The "Homing" operating mode is selected via SDO ( 176) with C5000 and confirmed with C Homing is started by activating the control bit 12. Control bit 12 = 1 (TRUE) 3. During the homing process the status bit 1 is active. Status bit 1 = 1 (TRUE) 4. The drive travels in positive direction. When the positive edge of the touch probe sensor () has been reached, the drive control knows the reference. 5. The drive continues traversing without interruption to the target position () which has been defined as offset to the home position (TP) under C When the target position is reached, homing is completed. Control bit 12 = 0 (FALSE) Status bit 2 = 1 (TRUE) 7. The zero position (C3012 plus the distance covered in C3011) is transmitted as actual position to the master control. 128

129 Commissioning Selection of the operating mode Selection of the operating mode The "Motion" application software supports the operating modes "Velocity Mode", "Homing Mode", "Interpolated Position Mode" (for travel according to setpoint selection), "Manual Jog" e.g. via GDC. Use C5000 to select the operating mode manually. The display code C5001 serves to confirm the currently set operating mode. The GDC includes the codes for selecting the operating mode in the parameter menu under Motion Operating mode. Fig.6 31 GDC view: Selection of the operating mode ECSXA538 Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C5000 OpMode 7 Selection of the operating mode 129 C5001 Mode_Op_Dis 2 Velocity mode Homing Mode Interpolated Position Mode Manual jog 137 Operating mode 129 Only display 2 Velocity mode Homing Mode Interpolated Position Mode Manual jog

130 6 Commissioning Selection of the operating mode "Velocity" operating mode "Velocity" operating mode The "Velocity Mode" enables the master control to transfer a speed profile to the ECSxM axis module via the MotionBus (CAN). Settings Select "CAN" control interface: C4010 = 0 Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C4010 Ctrl_Interf 0 Control interface CAN Control word is expected via PDO CAN1_IN No function Not used 2 No function Not used 3 C4040 Control word is generated by GDC/User or received by a master control via SDO. 4 No function Not used Select "Velocity Mode": C5000 = 2 The code C5000 (4C77h) is written via SDO ( 176). Selection confirmation: C5001 = 2 The selection of "Velocity Mode" is confirmed. Code C5001 (4C76h) must be read out via SDO. Activate "Velocity Mode": control bit 12 = 1 (TRUE) Definitions from the master control to the axis module: Speed signal (CAN1_nInW1_a) Ramp times (acceleration, deceleration and stop times) Retracting hardware limit switch 1. Deactivate limit switch monitoring: Control bit 1 = 1 (TRUE) Retracting from an activated hardware limit switch is enabled. 2. Reset fault message: Set control bit 11 = Activate "Velocity Mode": control bit 12 = 1 (TRUE) Note! Select "correct" direction of travel for speed profile. The active hardware limit switch must not be overtravelled while retracting. Positive hardware limit switch is active Retracting in negative direction Negative hardware limit switch is active Retracting in positive direction 4. Activate limit switch monitoring: Set control bit 1 = 0 (FALSE). 130

131 Commissioning Selection of the operating mode "Velocity" operating mode 6 Operating mode dependent bits in the control word Bit Name Value Reaction 1 Release limit switch 0 Limit switch monitoring is active 1 Limit switch monitoring is not active: After a TRIP RESET, the activated hardware limit switch can be retracted. 12 Activate "Velocity 0 Speed profile of the master control is not executed. Mode" 0 1 Start of the speed profile 1 Speed profile is executed. 1 0 Speed profile is interrupted or executed. 131

132 6 Commissioning Selection of the operating mode "Homing" operating mode "Homing" operating mode Note! No homing with absolute value encoders. Use C0098 to set another position than the one transmitted by the absolute value encoder. Settings Select "Homing Mode": C5000 = 6 Code C5000 (4C77h) is written via SDO ( 176). Selection confirmation: C5001 = 6 The selection of "homing mode" is confirmed. Code C5001 (4C76h) must be read out via SDO. Start homing: Control bit 12 = 1 (TRUE) Retracting hardware limit switch 1. Deactivate limit switch monitoring: Control bit 1 = 1 (TRUE) Retracting from an activated hardware limit switch is enabled. 2. Reset fault message: Set control bit 11 = Activate "Homing Mode": Control bit 12 = 1 (TRUE) Note! Select "correct" direction of travel for homing mode. The active hardware must not be overtravelled while retracting. Positive hardware limit switch is active Retracting in negative direction Negative hardware limit switch is active Retracting in positive direction 4. Activate limit switch monitoring: Set control bit 1 = 0 (FALSE). Operating mode dependent bits in the control word Bit Name Value Reaction 1 Release limit switch 0 Limit switch monitoring is active 1 Limit switch monitoring is not active: After a TRIP RESET, the activated hardware limit switch can be retracted. 12 Activate "Homing 0 Homing is not executed. Mode" 0 1 Start of homing 1 Homing is being executed. 1 0 Homing is interrupted or completed. 132

133 Commissioning Selection of the operating mode "Homing" operating mode 6 Operating mode dependent bits in the status word Bit Name Value Reaction 1 Homing is active 0 "Homing mode" is not active 1 Homing has been started by setting the control bit 12 = 1. No external setpoint changes are considered. 2 Reference known 0 Homing is being executed or has been aborted. 1 Homing is completed. Reference is known. 3 Reference error 0 No error during homing 1 Error during homing Function abort 4 Reference switch 0 No reference switch 1 Reference switch is active 133

134 6 Commissioning Selection of the operating mode Operating mode "Interpolated Position Mode" (IP Mode) Operating mode "Interpolated Position Mode" (IP Mode) The "IP mode"enables a travel according to setpoint selection. Settings Select "IP mode": C5000 = 7 Code C5000 (4C77h) is written via SDO ( 176). Selection confirmation: C5001 = 7 The selection of "IP mode" is confirmed. Code C5001 (4C76h) must be read out via SDO. Travel according to setpoint selection has not started yet. Activate "IP Mode": Control bit 12 = 1 (TRUE) Retracting hardware limit switch 1. Deactivate limit switch monitoring: Control bit 1 = 1 (TRUE) Retracting from an activated hardware limit switch is enabled. 2. Reset fault message: Set control bit 11 = Activate "IP Mode": Control bit 12 = 1 (TRUE) Note! Select "correct" direction of travel for position (setpoint). The active hardware must not be overtravelled while retracting. Positive hardware limit switch is active Retracting in negative direction Negative hardware limit switch is active Retracting in positive direction 4. Activate limit switch monitoring: Set control bit 1 = 0 (FALSE). Operating mode dependent bits in the control word Bit Name Value Reaction 1 Release limit switch 0 Limit switch monitoring is active 1 Limit switch monitoring is not active: After a TRIP RESET, the activated hardware limit switch can be retracted. 12 Activate IP mode 0 IP mode is not active 1 IP mode is active 13 Activate Pos_Latch 0 No touch probe 1 The position detection ( 135) will be started with the next touch probe edge. Note! The external setpoint can only be read if the control bit 12 = 1 (IP mode active). Otherwise, the drive must control the motor with the internal setpoint. 134

135 Commissioning Selection of the operating mode Operating mode "Interpolated Position Mode" (IP Mode) 6 Operating mode dependent bits in the status word Bit Name Value Reaction 1 IP mode is active 0 IP mode is not active 1 IP mode is active 2 Evaluate Pos_Latch 0 No touch probe 1 The active touch probe edge has completed the position detection. 3 Pos_Latch error 0 No error during position detection 1 Error during position detection Function abort 4 Touch probe sensor 0 No touch probe 1 Touch probe sensor is active Position detection (Pos_Latch) For position detection the drive traverses the sensor mark to a defined target. If "Touch Probe" is activated in the controller, the current position is saved. Note! The digital input X6/DI2 is double assigned with touch probe and homing switch. Ensure that both signals do not interact. Setting sequence: Setting Short description 1. Parameter setting. Set the following codes in the GDC parameter menu under Motion PosLatch: Set C3181 = 7 (nposlatchdiff) or Set control word bits 4, 5 and 6 = 7 [dec]. C0911 (MCTRL selection zero pulse/touch probe) 2. Save parameter set. Set C0003 = Activate position detection. Set control word bit 13 = 1 (TRUE). or Set C6001 = 1, 2 or 3: 1 = wait for rising edge 2 = wait for falling edge 3 = wait for rising or falling edge 4. Start positioning. Start positioning via the sensor in the IP mode by selecting a setpoint. 5. Evaluation of positioning With touch probe (X6/DI2 = HIGH) the position where the touch probe has occurred is saved in C6000. the difference to the actual position in "Word 2" of the process data telegram is transmitted. bit 4 in the status word is set to 1 (TRUE). Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0911 MCTRL TP sel. 0 MCTRL zero pulse/touch probe selection 0 Master pulse Feedback system at X7/X8 1 Touch probe Digital input X6/DI2 135

136 6 Commissioning Selection of the operating mode Operating mode "Interpolated Position Mode" (IP Mode) Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C3181 MonitorData 0 Monitor data selection Off 1 MCTRL_nPos_a Axis position 16 bits 2 DINT_TO_INT Following error 2 15 (MCTRL_dnPosSet_p) 3 MCTRL_nNAct_a Actual speed (N max = 2 14 ) 4 MCTRL_nMAct_a Actual torque (M max = 2 14 ) 5 MCTRL_nIAct_a Actual motor current (I max = 2 14 ) 6 MCTRL_nDCVolt_a Current DC bus voltage ( V) 7 nposlatchdiff Difference between actual position and position at touch probe (C6000) C6000 LatchPosition 0 Position at touch probe {1 inc} C6001 PosLatchAct 0 Activation: At touch probe (X6/DI2 = HIGH), the actual position is saved in C Not active 1 Wait for rising edge 2 Wait for falling edge 3 Wait for rising or falling edge C6002 TPReceived 0 Touch Probe (TP) recognised Only display 0 No TP recognised 1 TP with rising edge recognised 2 TP with falling edge recognised 3 TP with rising or falling edge recognised

137 Commissioning Selection of the operating mode "Manual Jog" operating mode "Manual Jog" operating mode When commissioning for the first time, it may be required to travel the axis module without active master control for optimisation reasons (e.g. using GDC). This is enabled by manual control through settings in C4010 and C4040. Settings Select control interface "C4040": C4010 = 3 Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C4010 Ctrl_Interf 0 Control interface CAN Control word is expected via PDO CAN1_IN No function Not used 2 No function Not used 3 C4040 Control word is generated by GDC/User or received by a master control via SDO. 4 No function Not used Set manual jog parameters: C3020 (speed: % of C0011 (maximum speed)) C3021 (acceleration time: s) C3022 (deceleration time: s) Select "Manual Jog" mode: C5000 = 128 Code C5000 (4C77h) is written via SDO ( 176). Selection confirmation: C5001 = 128 The selection of the "Manual Jog" mode is confirmed. Code C5001 (4C76h) must be read out via SDO. The drive does not respond to the application control word which is parameterised under C4040. (No response to the CAN control word.) Retracting hardware limit switch 1. Deactivate limit switch monitoring: C4040/Bit 1 = 1 (TRUE) Retracting from an activated hardware limit switch is enabled. 2. Reset fault message: Set C4040/Bit 11 = Select "correct" direction of travel via C4040/bit 13 and bit 14. Note! The active hardware limit switch must not be overtravelled during the retracting phase. Positive hardware limit switch is active Retracting in negative direction Negative hardware limit switch is active Retracting in positive direction 4. Activate limit switch monitoring: Set C4040/bit 1 = 0 (FALSE). 137

138 6 Commissioning Selection of the operating mode "Manual Jog" operating mode Operating mode dependent bits in the application control word (C4040) Hardware limit switch monitoring: Bit Name Value Reaction 1 Release limit switch 0 Limit switch monitoring is active 1 Limit switch monitoring is not active: After a TRIP RESET, the activated hardware limit switch can be retracted. Manual jog: Bit13 (JogCW) Value in Bit14 (JogCCW) Reaction 0 0 Stop Within the deceleration time C3022 the drive is braked to standstill. 0 1 Travel towards the positive hardware limit switch Within the acceleration time C3021 the drive is accelerated to the speed C Travel towards the negative hardware limit switch Within the acceleration time C3021 the drive is accelerated to the speed C Stop Within the deceleration time C3022 the drive is braked to standstill. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C4040 AppControl 0 Application control word when C4010 = 3 0 {1 bit} 1 Here, a drive can also be Bit 0 Toggle traversed without having a master control (e.g. using GDC). Bit1 Release limit switch Moreover it is possible to assign a control word via an SDO of a Bit2 Reserved master control to enable a manual jog ( 137) by the Bit3 QSP control. Bit4 Monitor data selection bit 0 Bit5 Monitor data selection bit 1 Bit6 Monitor data selection bit 2 Bit 7 Controller enable Bit 8 Operation inhibit (DISABLE) Bit 9 Controller inhibit (CINH) Bit10 Set fault message (TRIP SET) Bit11 Reset fault message (TRIP RESET) Bit12 Not used Bit13 JogCW Bit14 JogCCW Bit15 Reserved

139 Commissioning Controller enable Controller enable The controller only is enabled when the release by all decisive signal sources is provided (AND operation). If the controller is not enabled (inhibited), the causative signal source is displayed under C0183 (drive diagnostics) in the parameter menu under Diagnostics Current operation: Fig.6 32 GDC view: Diagnostics of current operation The following table shows the conditions for controller enable: ECSXA546 Source of the Controller inhibit Terminal X6/SI1 Terminal X6/SI2 Controller inhibited V (LOW level) V (LOW level) Controller enabled V (HIGH level) V (HIGH level) C0040 C0040 = 0 C0040 = 1 Operating module/keypad Trouble In case of TRIP In case of message Note For controller enable, X6/SI1 must be = HIGH and X6/SI2 = HIGH. key key Inhibiting with key is only possible if the key is assigned with "CINH" via C0469. TRIP RESET For check see 225. Control word Observe the function keys in the GDC: MotionBus (CAN) C3153/Bit 9 = 1 C3153/Bit 9 = 0 Key <F9> (inhibit/stop controller) ( 104) C4040 C4040/Bit 9 = 1 C4040/Bit 9 = 0 Note: With ECS M, the controller is enabled via the master control! Fieldbus module See Operating Instructions for the corresponding fieldbus module. Green LED is lit continuously if X6/SI1 = HIGH, X6/SI2 = HIGH, and the controller has been enabled via the master control. Green LED is blinking if X6/SI1 = HIGH and X6/SI2 = HIGH. (No enable via master control!) Note! All signal sources act like a series connection of switches which are independent of each other. 139

140 6 Commissioning Following error monitoring 6.13 Following error monitoring Following errors are monitored in all motion states of the drive. To configure the monitoring of following errors use C3030/C3031 (following error limits) and C3032/C3033 (reactions to following errors) in the GDC parameter menu under Motion Machine parameter. v [m/s] A B Fig.6 33 Following error Set profile Profile travelled The drive decelerates, there is no difference between set and actual position. Following error warning limit exceeded. (Difference between set position and actual position > C3030) End of the set profile t [s] ECSXA416 If the difference between set position and actual position is higher than the following error limit, the higher level control must activate a reaction according to the set error class. When the first following error limit in C3030 is reached, the first error reaction set in C3032 is activated. When the first following error limit in C3030 is reached, the second error reaction set in C3033 is activated. Note! For correct monitoring of following errors set: Limit value in C3031 > limit value in C3030 and error reaction in C3033 stronger than error reaction in C3032 Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C3030 FolloErrWarn Following error limit for enabling a warning 0 {1 inc} C3031 FolloErrFail Following error limit for enabling a FAIL QSP (Quick stop (QSP) is executed.) 0 {1 inc}

141 Commissioning Following error monitoring 6 Code No. Designation Possible settings Lenze/ {Appl.} Selection IMPORTANT C3032 FollErr1reac 2 First reaction when following error limit has been reached 0 TRIP 1 Message 2 Warning 3 Off 4 FAIL QSP C3033 FollErr2reac 4 Second reaction when following error limit has been reached 0 TRIP 1 Message 2 Warning 3 Off 4 FAIL QSP

142 6 Commissioning Evaluation of hardware limit switches 6.14 Evaluation of hardware limit switches Ensure a fail safe design of the hardware limit switches (NC contact, LOW active). The active level is set with C0114/x. A response to active hardware limit switches can be set via C3175. If a hardware limit switch is activated, the drive reacts as set and an error message is displayed. Positive hardware limit switch is activated: Fault no. x400 ("Pos HW End") Status bit 5 = 1 Negative hardware limit switch is activated: Fault no. x401 ("Neg HW End") Status bit 6 = 1 Note! Depending on the reaction and detection in the master control, retracting may not be possible anymore. This must be considered when the system is planned (e. g. hardware limit switches with key switch). Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C3175 HW EndReac 4 Response when a hardware limit switch is activated. 0 TRIP 1 Message 2 Warning 3 Off 4 FAIL QSP

143 Commissioning Quick stop (QSP) Quick stop (QSP) The quick stop function serves to brake the drive to standstill within an adjustable deceleration time. The function is triggered by: Control word bit 3 (QSP) = 1 (TRUE) LOW level at X6/DI1 The deceleration time for the braking process can be set with C0105 in the GDC parameter menu under Motion Machine parameter. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0042 DIS: QSP Quick stop status (QSP) Only display 0 QSP not active 1 QSP active C0105 QSP Tif 0.0 Deceleration time for quick stop (QSP) {0.001 s} Relating to speed variation n max (C0011)...0 rev./min. Behaviour when reaching the current limit The actual quick stop deceleration time prolongs if C0105 is set so shortly that the controller must operated at its current limits (I max, M max ). The following error occurring in this case in the position control loop is automatically modified internally so that the drive does not reverse when reaching standstill to process the following error but rests at standstill. Thus, the position control loop provides for a drift free standstill at quick stop (QSP). Tip! The quick stop function may require a setting of the position controller gain under C0254. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0254 Vp angle CTRL Phase controller gain (V p ) { }

144 6 Commissioning Operation with servo motors from other manufacturers Entering motor data manually 6.16 Operation with servo motors from other manufacturers Entering motor data manually If you operate servo motors of other manufacturers on the controller, you have to enter the motor data manually. The GDC includes the corresponding codes in the parameter menu under Motor/Feedb. Motor adjustment. Fig.6 34 GDC view: Manual setting of the motor data ECSXA544 Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection [C0006] Op mode 1 Operating mode of the motor control 1 Servo PM SM Servo control of synchronous motors 2 Servo ASM Servo control of asynchronous motors C0018 fchop 2 Switching frequency 1 4 khz sin 4 khz permanent PWM frequency 2 8/4 khz sin 8 khz PWM frequency with automatic derating to 4 khz at high load C0022 Imax current I max limit 0 {0.01 A} Device dependent list Max. current can be gathered from the technical data. C0058 Rotor diff 90.0 Rotor displacement angle for synchronous motors (C0095) {0.1 } [C0080] Res pole no. 1 Number of pole pairs of resolver 1 {1} 10 [C0081] Mot power 3.20 Rated motor power according to nameplate 0.01 {0.01 kw}

145 Commissioning Operation with servo motors from other manufacturers Entering motor data manually 6 Code No. [C0082] DIS:Rr Designation Possible settings IMPORTANT Lenze/ Selection {Appl.} Rotor resistance of the asynchronous motor Read only {0.001 } [C0084] Mot Rs 1.10 Stator resistance of the motor The upper limit is device dependent {0.01 } ECSxS/P/M/A ECSxS/P/M/A ECSxS/P/M/A ECSxS/P/M/A ECSxS/P/M/A ECSxS/P/M/A064 [C0085] Mot Ls 5.30 Leakage inductance of the motor 0.00 {0.01 mh} [C0087] Mot speed 3700 Rated motor speed 300 {1 rpm} [C0088] Mot current 7.0 Rated motor current 0.5 {0.1 A} [C0089] Mot 185 Rated motor frequency frequency 10 {1 Hz} 1000 [C0090] Mot voltage 325 Rated motor voltage 50 {1 V} 500 [C0091] Mot cos phi 1.0 cos of the asynchronous motor 0.50 {0.01} 1.00 [C0095] Rotor pos adj 0 Activation of rotor position adjustment of a synchronous motor C0058 shows the rotor displacement angle. C C0113 Service codes 0 Inactive 1 Active Only the Lenze service is allowed to make changes! 50 {1 %} 200 For controlling an asynchronous motor C0128 Tau motor 5.0 Thermal time constant of the motor {0.1 min} 25.0 For calculating the I 2 xt disconnection [C0418] Test Cur.Ctrl 0 Controller adjustment: Deactivated Deactivate test mode 1 Activated Activate test mode 145

146 6 Commissioning Operation with servo motors from other manufacturers Checking the direction of rotation of the resolver Checking the direction of rotation of the resolver The GDC contains the parameters/codes to be set in the parameter menu under Motor/Feedb. Motor adjustment. Code C0060 indicates the rotational angle of a revolution as a numerical value between This value must increase when the rotor rotates in CW direction (with view to the front of the motor shaft). If the values decrease, exchange the connections of Sin+ and Sin. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0060 Rotor pos Current rotor position Read only 0 {1 inc} revolution = 2048 increments

147 Commissioning Operation with servo motors from other manufacturers Adjusting current controller Adjusting current controller For optimum machine operation, the current controller must be adapted to the electrical values of the motor. Note! When using MCS motors... adjust the current controller with the maximum current intended for operation. Leakage inductance and stator resistance of the motor are known: The gain of the current controller V p and the integral action time of the current controller T n can be calculated by approximation: Current controller gain (V p ) Integral action time of the current controller (T n ) V p L1 S 250s T n L1 S R1 S L1 S R1 S Motor leakage inductance Motor stator resistance Note! Depending on the leakage inductance of the motor, the calculated values can be outside the adjustable range. In this case set a lower gain and a higher integral action time; adjust the current controller metrologically ( 148). For applications with high current controller dynamics the pilot control of the current controller outputs can be activated with C0074 (C0074 = 1). For this, it is vital to enter the correct values for the stator resistance (C0084) and leakage inductance (C0085).These can be obtained from the data sheet of the motor used! 147

148 6 Commissioning Operation with servo motors from other manufacturers Adjusting current controller Leakage inductance and stator resistance of the motor are not known: The current controller can be optimised metrologically with a current probe and an oscilloscope. For this, a test mode is available in which the current C0022 x 2 flows in phase U after controller enable. Stop! Avoiding damage on the motor and the machine During the controller adjustment the motor must be able to rotate freely. The test current must not exceed the maximum permissible motor current. Always adjust the current controller at a switching frequency of 8 khz. Observe the current step in phase U to adjust the current controller. Setting sequence 1. Switching frequency = set 8 khz (C0018 = 2). 2. Set the quantity of the test current under C0022: Start with low current, e.g. half rated motor current. 3. Activate the test mode with C0418 = Enable the controller ( 139) Press key <F8> in the GDC. Have the synchronous motor adjusted. Asynchronous motor is in standstill. 5. Enable and inhibit the controller several times in a row. In doing this, alter the current controller gain (C0075) and the current controller reset time (C0076) so that the current characteristic is free of harmonics. 6. After the adjustment has been successfully completed, deactivate the test mode with C0418 = If necessary, change the switching frequency via C

149 Commissioning Operation with servo motors from other manufacturers Effecting rotor position adjustment Effecting rotor position adjustment Note! Resolver/absolute value encoder with Hiperface interface If the rotor zero phase is not known, the rotor position adjustment at commissioning only has to be carried out once. In the case of multi turn absolute value encoders the traversing range has to be within the display area of the encoder if it is limited ( revolutions). Incremental encoder / SinCos encoder with zero track If these encoder types are used for the operation of synchronous motors, the rotor position adjustment has to be carried out every time the low voltage supply is switched on. The rotor position must be adjusted if: A servo motor from another manufacturer is operated on the controller. Another encoder has been mounted subsequently. A defective encoder has been replaced. The rotor position can only be adjusted if: The resolver is polarised correctly. The current controller has been adjusted. The GDC contains the parameters or codes to be set in the parameter menu under Motor/Feedback Feedback. Fig.6 35 GDC view: Commissioning of further feedback systems ECSXA

150 6 Commissioning Operation with servo motors from other manufacturers Effecting rotor position adjustment Setting sequence 1. Inhibit controller. ( 139 ) Press key <F9> in the GDC. Green LED is blinking, red LED is off 2. Unload motor mechanically. Separate motor from gearbox or machine. Where required, remove toothed lock washers, gear wheels, etc. from the motor shaft. Where required, support holding torques held by a mounted engine brake by retainers. 3. Deactivate "Safe torque off" ( 60), so that the motor can be energised during rotor position adjustment. X6/SI1 = HIGH X6/SI2 = HIGH 4. Open holding brake (if available). 5. Activate rotor position adjustment with C0095 = Enable controller. ( 139) Press key <F8> in the GDC. The rotor position adjustment program of the controller is started: The rotor rotates half a revolution in 16 steps (for resolver with 1 pole pair: 180 electrically 180 mechanically). C0095 is reset to 0 after one revolution. The rotor zero phase is saved in C0058. (For absolute value encoders (Hiperface, single turn/multi turn) at X8, C0058 is always "0".) Danger! Uncontrolled movements of the drive after an Sd7 fault for absolute value encoders If the rotor position adjustment in the case of absolute value encoders is completed with the fault message "Sd7", ( 230) an assignment of the rotor position to the feedback system could not be carried out. In this case the drive may perform uncontrolled movements after controller enable. Possible consequences: Death or severest injuries Destruction or damage of the machine/drive Protective measures: Repeat rotor position adjustment (starting with step 1). Check wiring and interference immunity of the encoder at X8. 7. Inhibit controller. ( 139 ) Press key <F9> in the GDC. Green LED is blinking, red LED is off 150

151 Commissioning Operation with servo motors from other manufacturers Effecting rotor position adjustment 6 8. Save the data determined by the controller with C0003 = 1. Tip! The values for C0058 and C0095 only are displayed in the GDC if you place the bar cursor on them and read back the code using function key <F6>. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0058 Rotor diff 90.0 Rotor displacement angle for synchronous motors (C0095) {0.1 } [C0095] Rotor pos adj 0 Activation of rotor position adjustment of a synchronous motor C0058 shows the rotor displacement angle. 0 Inactive 1 Active

152 6 Commissioning Optimising the drive behaviour after start Speed controller adjustment 6.17 Optimising the drive behaviour after start For applications with high current controller dynamics, the pilot control for the current controller can be adjusted under C0074: Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0074 Dynamics 0 {1} 0 Normal 1 Enhanced Pilot control of the current controller for higher dynamics Speed controller adjustment The speed controller can only be set correctly when the system constellation has been completed. Observe that the input variables and output variables of the speed controller are scaled: Input: scaling on n max (C0011) Output: scaling on I max (C0022) C0011 and C0022 therefore have a direct influence on the proportional gain of the speed controller (C0070). The speed controller cannot be optimally adjusted if the current controller is set incorrectly. the time constant for the actual value filter is set too high (C0497). the connection of the axis module to PE is bad, as then the speed signals and current signals are "noisy". there are elastic or loose connections between the drive and the load. The speed controller is designed as an ideal PID controller. The codes for adjusting the speed controller can be found in the parameter menu of the GDC under Controller settings Speed. Fig.6 36 GDC view: Adjustment of the speed controller ECSXA

153 Commissioning Optimising the drive behaviour after start Speed controller adjustment 6 Parameter setting Via C0070 you set the proportional gain (V pn ): Enter approx. 50 % of the speed setpoint (100 % = = n max ). Increase C0070 until the drive becomes instable (pay attention to engine noises). Reduce C0070, until the drive runs stable again. Reduce C0070 to approx. half the value. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0070 Vp speedctrl 3.0 Proportional gain of speed controller (V pn ) 0.00 { 0.01} The reset time (T nn ) is set via C0071: Reduce C0071 until the drive becomes instable (pay attention to engine noises). Increase C0071, until the drive runs stable again. Increase C0071 to approx. the double value. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0071 Tn speedctrl 24.0 Reset time speed controller (T nn ) 1.0 {0.5 ms} The derivative gain (T dn ) is set via C0072: Increase C0072 during operation until an optimal control mode is reached. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0072 Td speedctrl 0.0 Derivative gain of speed controller (T dn ) 0.0 {0.1 ms}

154 6 Commissioning Optimising the drive behaviour after start Adjustment of field controller and field weakening controller Adjustment of field controller and field weakening controller Stop! Field weakening operation can only be effected for asynchronous motors. The available torque is reduced by the field weakening. In order to optimise the machine operation in the field weakening range, you can set the field controller and the field weakening controller accordingly. There is field weakening if the output voltage of the controller reaches its maximum with increasing speed and cannot be further increased. The maximum possible output voltage depends on the respective DC bus voltage (mains voltage). the voltage reduction by the controller behaviour. the voltage drop at the mains choke. Experience values for the voltage drop under the influence of the mains choke and inverter are between %. Max.outputvoltage[V] mainsvoltage[v] voltagedrop[%] In the GDC you ll find the codes for adjusting the field controller or field weakening controller in the parameter menu under controller setting: Fig.6 37 GDC view: Field controller / field weakening controller adjustment ECSXA

155 Commissioning Optimising the drive behaviour after start Adjustment of field controller and field weakening controller Adjusting the field controller The field controller settings depend on the motor data. Setting sequence 1. Stop the PLC program: C2108 = 2 As of operating system version 7.0 (see nameplate), this is no longer necessary, because C0006 (see 2.) can also be written when the PLC program is running! 2. Set motor control for asynchronous motors: C0006 = 2 The motor nameplate data must be entered correctly! 3. Read rotor time constant T r (C0083). 4. Read magnetising current I d (C0092). 5. Calculate field controller gain V pf and enter in C0077. V pf T r(c0083) I d (C0092) 875s I max I max Maximum current of axis module 6. Enter rotor time constant T r as field controller integral action time T nf in C

156 6 Commissioning Optimising the drive behaviour after start Adjustment of field controller and field weakening controller Field weakening controller adjustment The field weakening controller determines the speed performance of the asynchronous motor in the field weakening range. The field weakening controller can only be set correctly when the system constellation has been completed and is under load. Note! An excessive value of I max (C0022) can cause a malfunction of the drive in the field weakening range of the asynchronous motor. For this reason, the current is limited in terms of speed in the field weakening range. The limitation has a 1/n characteristic and is derived from the motor parameters. The limitation can be adjusted with the stator leakage inductance (C0085): Low values cause a limitation at higher speeds. Higher values cause a limitation at lower speeds. Setting sequence: 1. Set gain V p : C0577 = V p must not be "0"! 2. Set integral action time T n : C0578 = ms 3. Select a speed setpoint so that the motor is operated in the field weakening range. 4. Observe the speed curve If the speed takes an irregular course, the field weakening controller must be readjusted. The field weakening controller must be provided with a distinct integral action. 156

157 Commissioning Optimising the drive behaviour after start Resolver adjustment Resolver adjustment For resolver adjustment, mainly component tolerances of the resolver evaluation are compensated in the device. A resolver error characteristic is not included. The resolver adjustment is required if the speed characteristic is unstable. is carried out by C0417 = 1 while the motor is idling. is started after controller enable has been effected. It stops automatically after 16 shaft revolutions by selecting a setpoint or by manual rotation in the inhibited state (X6/SI1 or X6/SI2 = LOW). If it is not possible to adjust the resolver (due to a fault or a defective cable), the original adjustment values can be restored with C0417 = 2. The GDC contains the parameters or codes to be set in the parameter menu under Motor/Feedback Feedback. Fig.6 38 GDC view: Resolver adjustment ECSXA

158 7 Parameter setting General information 7 Parameter setting 7.1 General information The controller can be adapted to your application by setting the parameters. A detailed description of the functions can be found in the chapter "Commissioning" ( 79). The parameters for the functions are stored in numbered codes: The codes are marked in the text with a "C". The code table ( 238) provides a quick overview of all codes. The codes are sorted in numerical ascending order, thus serving as a "reference book". Parameter setting with keypad XT or PC/laptop Detailed information on parameter setting with the keypad XT can be found in the following chapters. Detailed information... on the parameter setting with a PC/laptop can be found in the documentation of the parameter setting and operating program "Global Drive Control" (GDC). In addition to parameter setting the keypad XT or PC/laptop serves to: Control the controller (e. g. inhibiting or enabling) Select the setpoints Display operating data Transfer parameter sets to other controllers (only via PC/laptop). Parameter setting with a bus system Detailed information... on the parameter setting with a bus system can be found in the documentation of the communication module to be applied ( 289). 158

159 Parameter setting Parameter setting with "Global Drive Control" (GDC) Parameter setting with "Global Drive Control" (GDC) With the "Global Drive Control" (GDC) parameterisation and operating program, Lenze provides a plain, concise and compatible tool for the configuration of your application specific drive task with the PC or laptop: The GDC input assistant offers a comfortable motor selection. The menu structure supports the commissioning process by its clear structuring. L X14 Fig.7 1 Using the GDC Lenze parameter program "Global Drive Control" (GDC) PC or laptop PC system bus adapter (EMF2173IB/EMF2177IB) with connecting cable Sub D plug with 3 pole cable 3 pole plug (CAG CAL CAH) from ECSZA000X0B connector set ECSxS/P/M/A axis module ECSXA

160 Menu Code Para Menu SHPRG Menu Code Para 50.00_Hz MCTRL-NOUT 7 Parameter setting Parameter setting with the XT EMZ9371BC keypad Connecting the keypad 7.3 Parameter setting with the XT EMZ9371BC keypad The keypad is available as an accessory. A full description can be found in the documentation for the keypad Connecting the keypad SHPRG _Hz MCTRL-NOUT EMZ9371BC SHPRG Code Para GLOBAL DRIVE E82ZWLxxx E82ZBBXC Init Hz 20 % Hz 20 % 9371BC018 Connect the keypad to the AIF interface (X1) of the axis module/power supply module. It is possible to connect/disconnect the keypad during operation. As soon as the keypad is supplied with voltage, it carries out a short self test. The operation level indicates when the keypad is ready for operation: Current status of the axis module/power supply module Code number, subcode number, and current value Active fault message or additional status message Current value in % of the status display defined in C0004 Press to leave the operating level. 160

161 Parameter setting Parameter setting with the XT EMZ9371BC keypad Description of the display elements Description of the display elements SHPRG Menu Code Para 50.00_Hz MCTRL-NOUT Fig.7 2 Keypad: front view 9371BC002 Status displays Display Meaning Explanation Ready for operation Pulse inhibit active Power outputs inhibited Adjusted current limitation is exceeded in motor mode or generator mode Speed controller 1 within its limitation Drive is torque controlled Only active for operation with Lenze devices of the 9300 series! Active fault Parameter acceptance Display Meaning Explanation Parameter is accepted immediately Device immediately operates with the new parameter value. SHPRG Parameter must be confirmed with Device operates with the new parameter value after being confirmed. SHPRG When the controller is inhibited, the Device operates with the new parameter parameter must be confirmed with value after the controller has been enabled again. None Display parameters Cannot be changed. Active level Display Meaning Explanation Menu Active menu level Selection of main menu and submenus No menu for ECSxE... power supply module! Code Active code level Selection of codes and subcodes Para Active parameter level Change of parameters in the codes or subcodes None Active operating level Display of operating parameters Short text Display Meaning Explanation Alphanumeric al Contents of the menus, meaning of the codes and parameters Display of C0004 in % and the active fault in the operating level 161

162 7 Parameter setting Parameter setting with the XT EMZ9371BC keypad Description of the function keys Number Active level Meaning Explanation Menu level Menu number Display is only active when operating Lenze devices of the 8200 vector or 8200 motec series. No menu for ECSxE... power supply module! Code level Four digit code number Number Active level Meaning Explanation Menu level Submenu number Display is only active when operating Lenze devices of the 8200 vector or 8200 motec series. No menu for ECSxE... power supply module! Code level Two digit subcode number Parameter value Parameter value with unit Cursor The figure over the cursor can be directly changed in the parameter level. Function keys For description see the following table Description of the function keys Note! Key combinations with : Press and keep it pressed, then press second key in addition. Key Function Menu level 1) Code level Parameter level Operating level Load predefined configurations in the menu "Short setup" 2) Change between menu items Quick change between menu items Change to parameter level Change code number Quick change of code number Change between main menu, submenus and code level Cancel function of key, the LED in the key goes out. Inhibit the controller, LED in the key lights up. Reset fault (TRIP reset): 1. Remove cause of fault 2. Press 3. Press Change to operating level Accept parameters when SHPRG or SHPRG is displayed Change figure over cursor Quick change of figure over cursor cursor to the right cursor to the left 1) No menu for ECSxE... power supply module 2) Only active when operating Lenze devices of the 8200 vector or 8200 motec series. Change to code level 162

163 Parameter setting Parameter setting with the XT EMZ9371BC keypad Altering and saving parameters Altering and saving parameters All parameters by means of which you can parameterise or monitor the axis module/power supply module are saved in so called codes. The codes are numbered and are marked with a "C" in the documentation. In some codes the parameters are saved in numbered "Subcodes", so that the parameter setting remains concise (e. g. C0517 user menu). Stop! Your settings have an effect on the current parameters in the RAM. You must store your settings as a parameter set to prevent that they will get lost when switching the mains! Step Keys Action 1. Select menu Select the desired menu with arrow keys. 2. Change to code level Display of first code in the menu 3. Select code or subcode Display of the current parameter value 4. Change to parameter level 5. If SHPRG is displayed, inhibit The drive is idling. controller 6. Change parameters A Move cursor under the digit to be changed 7. Accept changed parameter B Change digit Display SHPRG or SHPRG Display Change digit quickly Confirm change to accept parameter Display "OK" The parameter was accepted immediately. 8. If necessary, enable controller The drive should be running again. 9. Change to code level A Display of operating level B Display of the code with changed parameters 10. Change further parameters Restart the "loop" at step 1. or step Save changed parameters Select parameter set in which the parameters are to be saved permanently 12. Change to code level A Select code C0003 "PAR SAVE" from the menu "Load/Store" B Change to parameter level Display "0" and "Ready" C Save as parameter set 1: set "1" "Save PS1" D When "OK" is displayed, the settings are permanently saved. A Display of operating level B Display C0003 "PAR SAVE" 163

164 7 Parameter setting Parameter setting with the XT EMZ9371BC keypad Menu structure Menu structure For easy operation, the codes are clearly arranged in function related menus: Main menu Submenus Description Display Display USER menu Codes defined under C0517 Code list User code list Load / Store Multitasking Diagnostics SystemBlocks Terminal I/O Controller Motor/Feedb. Monitoring Actual info History MCTRL DCTRL All available codes List of all application specific codes Parameter set management Parameter set transfer, restore delivery state Diagnostics Display codes to monitor the drive Fault analysis with history buffer Configuration of the main function blocks Motor control Internal control Linkage of the inputs and outputs with internal signals AIn1 Analog input 1 DIGIN Digital inputs DIGOUT Digital outputs DFIN Digital frequency input DFOUT Digital frequency output Configuration of internal control parameters Speed Current Phase Field Field weak Motor adj Feedback Speed controller Current controller or torque controller Phase controller Field controller Field weakening controller Input of motor data, configuration of speed feedback Motor data Configuration of feedback systems Configuration of monitoring functions LECOM/AIF LECOM A/B AIF interface Status word Configuration of operation with communication modules Serial interface Process data Display of status words 164

165 Parameter setting Parameter setting with the XT EMZ9371BC keypad Menu structure 7 Main menu Display System bus 1) FCODE Identify Submenus Display Management CAN IN1 CAN OUT1 CAN IN2 CAN OUT2 CAN IN3 CAN OUT3 Status word Sync.manag. Diagnostics Drive Op Keypad Description System bus/motionbus (CAN) configuration CAN communication parameters CAN object 1 CAN object 2 CAN object 3 Display of status words CAN diagnostics Configuration of free codes Identification Software version of basic device Software version of keypad 1) For ECSxS/P/M... ECS modules the configuration of the MotionBus (CAN) is carried out on the "System bus" menu level! 165

166 SHPRG Menu Code Para 8 Configuration 8 Configuration By configuring the axis module you can adapt the drive system to your application. The axis module can be configured via the following interfaces: X1 AIF (automation interface) For connecting the keypad XT EMZ9371BC or another communication module ( 289) with which you can access the codes. X14 system bus (CAN) interface PC interface/hmi for parameter setting and diagnostics (e.g. with the Lenze parameter setting and operating program "Global Drive Control") or Interface to a decentralised I/O system Systembus (CAN) _Hz MCTRL-NOUT MotionBus (CAN) X1 X1 X1 X1 X1 X4 X4 X4 X4 X4 X14 X14 X14 X14 ECSXA028 Fig.8 1 Example: Wiring of the MotionBus (CAN) and system bus (CAN) XT EMZ9371BC keypad or another communication module PC/laptop or HMI Decentralised I/O system Higher level master system / MotionBus control ECSxE...power supply module ECSxx...axis modules 166

167 Configuration General information about the system bus (CAN) Structure of the CAN data telegram General information about the system bus (CAN) Note! The information on this chapter will be part of the "CAN Communication Manual" at a later date. All Lenze drive and automation systems are equipped with an integrated system bus interface for the networking of control components on field level. Via the system bus interface, for instance process data and parameter values can be exchanged between the nodes. In addition, the interface enables the connection of further modules such as distributed terminals, operator and input devices or external controls and host systems. The system bus interface transmits CAN objects following the CANopen communication profile (CiA DS301, version 4.01) developed by the umbrella organisation of CiA (CAN in Automation) in conformity with the CAL (CAN Application Layer). Tip! For further information visit the homepage of the CAN user organisation CiA (CAN in Automation): cia.org Structure of the CAN data telegram Control field CRC delimit. ACK delimit. Start RTR bit CRC sequence ACK slot End Identifier User data ( bytes) Network management Process data 1 bit 11 bits 1 bit 6 bits Parameter data 15 bits 1 bit 1 bit 1 bit 7 bits Fig.8 2 Basic structure of the CAN telegram Identifier The identifier determines the priority of the message. Moreover, the following is coded: The CAN node address (device address in the CAN network) of the node which is to receive the CAN telegram. See also chapter "Addressing of the parameter and process data objects" ( 182). The type of user data to be transferred 167

168 8 Configuration General information about the system bus (CAN) Communication phases of the CAN network (NMT) User data The user data area of the CAN telegram either contains network management data, process data or parameter data: User data Network management data (NMT data) Process data (PDO, Process Data Objects) Parameter data (SDO, Service Data Objects) Description The information serves to establish communication via the CAN network Process data are transmitted via the process data channel. The process data serve to control the controller. Process data can be accessed directly by the higher level host system. The data are, for instance, stored directly in the I/O area of the PLC. It is necessary that the data can be exchanged between the host system and the controller within the shortest time possible. In this connection, small amounts of data can be transferred cyclically. Process data are transmitted between the higher level host system and the controllers to ensure a permanent exchange of current input and output data. Process data are not stored in the controller. Process data are, for instance, setpoints and actual values. Parameter data are transferred via the parameter data channel and acknowledged by the receiver, i.e. the receiver gets a feedback whether the transmission was successful. Parameter data of Lenze devices are called codes. The parameter data channel enables access to all Lenze codes and all CANopen indexes. Parameters are set, for instance, for the initial commissioning of a plant or when material of a production machine is exchanged. Usually the transfer of parameters is not time critical. Parameter changes are stored in the controller. Parameter data are, for instance, operating parameters, diagnostic information and motor data. Tip! The other signals refer to the transfer features of the CAN telegram that are not described in these instructions. For further information visit the homepage of the CAN user organisation CiA (CAN in Automation): cia.org Communication phases of the CAN network (NMT) With reference to communication the drive knows the following states: State "Initialisation" (Initialisation) "Pre operational" (before operation) "Operational" (ready for operation) "Stopped" Explanation After the controller is switched on the initialisation phase is run through. During this phase, the controller is not involved in the data transfer on the bus. Furthermore it is possible to run through a part of the initialisation in each NMT state due to the transfer of different telegrams (see "State transitions"). Here, all parameters already set are rewritten with their standard values. After completing the initialisation the drive is automatically in the "Pre Operational" state. The drive can receive parameter data. The process data are ignored. The drive can receive parameter data and process data. Only network management telegrams can be received. 168

169 Configuration General information about the system bus (CAN) Communication phases of the CAN network (NMT) 8 Status transitions (1) Initialisation (14) (2) (11) Pre-Operational (13) (4) (5) (7) (10) (3) (6) Stopped (12) Operational (8) (9) Fig.8 3 State transitions in the CAN network (NMT) E82ZAFU004 State transition Command (hex) Network status after change (1) Initialisation (2) Pre Operational Effects on process and parameter data after status change Initialisation starts automatically when the mains is switched on. During the initialisation phase the drive is not involved in the data exchange. After the initialisation is completed, the node automatically changes to the "Pre Operational" state. In this phase, the master determines the way the controllers take part in the communication. From here on, the states are changed by the master for the entire network. A target address included in the command specifies the receiver(s). (3), (6) 01xx Operational Network management telegrams, sync, emergency, process data (PDO) and parameter data (SDO) are active (corresponds to "Start Remote Node") Optional: During the change event controlled and time controlled process data (PDO) are transmitted once. (4), (7) 80xx Pre Operational Network management telegrams, sync, emergency and parameter data (SDO) are active (corresponds to "Enter Pre Operational State") (5), (8) 02xx Stopped Only network management telegrams can be received. (9) (10) (11) (12) (13) (14) 81xx 82xx Initialisation Initialisation of all parameters in the communication module with the values stored (corresponds to "Reset Node") Initialisation of parameters relevant to communication (CiA DS 301) in the communication module with the values stored (corresponds to "Reset Communication") xx = 00 hex xx = node ID With this assignment, all devices connected are addressed by the telegram. The status can be changed for all devices at the same time. If a node address is indicated, the status will only be changed for the device addressed. 169

170 8 Configuration General information about the system bus (CAN) Communication phases of the CAN network (NMT) Network management (NMT) The telegram structure used for the network management contains the identifier and the command included in the user data which consists of the command byte and the node address. Identifier Value = 0 11 bits User data Only contains command 2bytes Fig.8 4 Telegram for switching over the communcation phases The communication phases are changed over by a node, the network master, for the entire network. The changeover can also be effected by a controller. After power on a telegram is sent with a certain delay that changes the status of the whole drive system to "Operational". The delay time can be set via the following codes: Interface code x1 Automation interface (AIF) C2356/1 X4 ECSxS/P/M: MotionBus (CAN) C0356/1 ECSxA: system bus (CAN) X14 System bus (CAN) C2456/1 Note! Communication via process data is only possible with a status change to operational"! Example: For changing the status of all nodes on the bus from "pre operational" to operational" via the CAN master, the following identifier and user data must be set in the telegram: Identifier: 00 (broadcast telegram) User data: 0100 (hex) 170

171 Configuration General information about the system bus (CAN) Process data transfer Process data transfer Definitions Process data telegrams between host and drive are distinguished as follows: Process data telegrams to the drive Process data telegrams from the drive The CANopen process data objects are designated as seen from the node s view: RPDOx: process data object received by a node TPDOx: process data object sent by a node Available process data objects The following process data objects are available for the ECS axis modules via the interfaces X1, X4 and X14: Interface RPDOs TPDOs In axis module ECSxS ECSxP ECSxM ECSxA x1 Automation interface (AIF) X4 ECSxS/P/M: MotionBus (CAN) ECSxA: system bus (CAN) X14 System bus (CAN) XCAN1_IN XCAN1_OUT XCAN2_IN XCAN2_OUT XCAN3_IN XCAN3_OUT CAN1_IN CAN1_OUT CAN2_IN CAN2_OUT CAN3_IN CAN3_OUT CANaux1_IN CANaux1_OUT CANaux2_IN CANaux2_OUT CANaux3_IN CANaux3_OUT Structure of the process data Each process data telegram has a maximum user data length of eight bytes. Process data input telegram (RPDO) The process data input telegram transmits control information to the axis module. The 8 bytes of user data can be freely assigned. Identifier User data (8 bytes) 11 bits 00 hex 00 hex 00 hex 00 hex 00 hex 00 hex 00 hex 00 hex Fig.8 5 Structure of the process data input telegram (RPDO) 171

172 8 Configuration General information about the system bus (CAN) Process data transfer Process data output telegram (TPDO) The process data output telegram indicates status information from the axis module. E.g.: Current status of the axis module Status of the digital inputs States of internal analog values Fault/error messages This information enables the master system to react. The 8 bytes of user data can be freely assigned. Identifier User data (8 bytes) 11 bits 00 hex 00 hex 00 hex 00 hex 00 hex 00 hex 00 hex 00 hex Fig.8 6 Structure of the process data output telegram (TPDO) Transfer of the process data objects Process data objects RPDOs TPDOs XCAN1_IN CAN1_IN CANaux1_IN XCAN2_IN CAN2_IN CANaux2_IN XCAN3_IN CAN3_IN CANaux3_IN XCAN1_OUT CAN1_OUT CANaux1_OUT XCAN2_OUT CAN2_OUT CANaux2_OUT XCAN3_OUT CAN3_OUT CANaux3_OUT Data transmission cyclic (sync controlled) cyclic cyclic cyclic (sync controlled) time or event controlled time or event controlled The cyclic data transmission is activated for each PDO only by a sync telegram. The event controlled data transmission is caused if a value in the corresponding output object changes. For the time controlled transmission the boot up time, cycle time or delay time can be set via the following codes. Interface Code x1 Automation interface (AIF) C2356 X4 ECSxS/P/M: MotionBus (CAN) C0356 ECSxA: system bus (CAN) X14 System bus (CAN) C

173 Configuration General information about the system bus (CAN) Process data transfer Cyclic process data objects Cyclic process data objects are determined for a master system. PDO1, cyclic process data (setpoints and actual values) PAW CAN1_IN Axis module ECSxS/P/M/A... PEW CAN1_OUT Host system Fig.8 7 Example: Process data transfer via CAN1_IN and CAN1_OUT PIW Process data input word POW Process data output word For the quick exchange of process data from or to the master respectively one process data object for input signals (Rx PDO1) and one process data object for output signals (Tx PDO1), each with eight bytes of user data, is provided. 173

174 8 Configuration General information about the system bus (CAN) Process data transfer Synchronisation of PDOs with SYNC controlled transmission A special telegram, the sync telegram, is used to ensure that the cyclic process data can be read and will be accepted by the controller. The sync telegram is the trigger point for the transmission of process data from the controllers to the master and for the acceptance of process data from the master in the controllers. For SYNC controlled process data processing, the sync telegram is to be generated accordingly. Sync telegram Sync telegram TPDOs RPDOs Cycle time Fig.8 8 Sync telegram 1. After the sync telegram has been received, the controllers send the synchronous process data to the master (TPDOs). The master reads them as process input data. 2. When the transmission process has been completed, the controllers receive the process output data from the master (RPDOs). All further telegrams (e.g. parameters or event controlled process data) are accepted non cyclically by the controllers when the transmission is completed. The non cyclic data are not represented in the above illustration. They must be taken into account when dimensioning the cycle time. 3. The data are accepted by the controller with the next sync telegram. Tip! The response to a sync telegram is determined by the transmission type selected. Note! Information on how to set the synchronisation can be found from

175 SHPRG Menu Code Para Configuration General information about the system bus (CAN) Process data transfer Event controlled process data objects The event controlled process data objects in particular are suitable for the data exchange from axis module to axis module and for decentralised terminal extensions. However, they can also be used by a host system. Systembus (CAN) _Hz MCTRL-NOUT MotionBus (CAN) X4 X1 X4 Tx-PDO2 Rx-PDO2 Tx-PDO2 Rx-PDO2 Tx-PDO2 Rx-PDO2 X4 X4 X4 X14 X14 X14 X14 Fig.8 9 Example: Event controlled process data objects PDO2 ECSXA219 By means of the process data objects, simple binary signals (e. g. states of digital input terminals) or also complete values in 16 and 32 bit (e. g. analog signals) can be transmitted. Event controlled process data objects with adjustable cycle time (optional) The output data is transmitted event controlled if a value changes within the user data (8bytes) or cyclically with the cycle time set: Interface Code x1 Automation interface (AIF) C2356 X4 ECSxS/P/M: MotionBus (CAN) C0356 ECSxA: system bus (CAN) X14 System bus (CAN) C

176 SHPRG Menu Code Para 8 Configuration General information about the system bus (CAN) Parameter data transfer Parameter data transfer SDO1 SDO2 Systembus (CAN) _Hz MCTRL-NOUT MotionBus (CAN) X1 X4 X4 X4 X4 X4 X14 X14 X14 X14 ECSXA220 Fig.8 10 Parameters Parameter data channels for parameterising ECS are values which are stored in Lenze controllers under a code. are carried out, for instance, for initial commissioning of a plant or when material of a production machine is exchanged. are transmitted with low priority. Parameter data is transferred as SDOs (Service Data Objects) via the system bus and acknowledged by the receiver. The SDOs enable the reading and writing access to the object directory. The CAN bus interfaces X4 and X14 are provided with two separated parameter data channels each which serve to simultaneously connect different devices for parameter setting and diagnostics. The codes for parameter setting and diagnostics of the automation interface (AIF) X1 and the CAN bus interfaces X4 and X14 are divided in separated areas: Interface Code range x1 Automation interface (AIF) C23xx X4 ECSxS/P/M: MotionBus (CAN) C03xx ECSxA: system bus (CAN) X14 System bus (CAN) C24xx 176

177 Configuration General information about the system bus (CAN) Parameter data transfer User data Structure of the parameter data telegram User data (up to 8 bytes) 1st byte 2nd byte 3rd byte 4th byte 5th byte 6th byte 7th byte 8th byte Data 1 Data 2 Data 3 Data 4 Command Index Index Low word High word Subindex Low byte High byte Low byte High byte Low byte High byte Display Note! The user data are displayed in Motorola format. Examples of parameter data transfer can be found from 180. Command The command contains services for writing and reading parameters and the information on the length of the user data: Bit 7 MSB Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 LSB Command Command specifier (cs) Toggle (t) Length e s Write request Write response = 4 bytes 01 = 3 bytes 0 0 Read request = 2 bytes = 1 byte Read response Error response Tip! Further commands are defined in the CANopen specifications DS301,V4.02 (e.g. segmented transfer). 177

178 8 Configuration General information about the system bus (CAN) Parameter data transfer The following information are contained or must be entered in the command. Command Write request (Transmit parameters to the drive) Write response (Acknowledgement, controller response to write request) Read request (Request to read a controller parameter) Read response (Response to read request with current value) Error response (The controller indicates a communication error) 4 byte data (5th... 8th byte) 2 byte data (5th and 6th byte) 1 byte data (5th byte) Block hex dec hex dec hex dec hex dec B 43 2F B 75 4F Command "ErrorResponse": In the event of a communication error, the node addressed generates an "error response". This telegram always contains the value "6" in data 4 and an error code in data 3. The error codes are standardised according to DS301, V4.02. Addressing by index and subindex The parameter or Lenze code is addressed with these bytes according to the following formula: Index = (Lenze code number) Data1...Data4 Parameter value length depending on the data format Parameter value (Length: 1 byte) Parameter value (length: 2 bytes) Low byte High byte Low word Parameter value (length: 4 bytes) High word Low byte High byte Low byte High byte Note! Lenze parameters are mainly represented as data type FIX32 (32bit value with sign, decimally with four decimal positions). To obtain integer values, the desired parameter value must be multiplied by 10,000 dec. The parameters C0135 and C0150 must be transmitted bit coded and without a factor. 178

179 Configuration General information about the system bus (CAN) Parameter data transfer 8 Error messages User data (up to 8 bytes) 1st byte 2nd byte 3rd byte 4th byte 5th byte 6th byte 7th byte 8th byte Command Index Low byte Index High byte Subindex Display Byte 1: In the command byte the code 128 dec or 80 hex indicates that a fault has occurred. Byte 2, 3 and 4: In these bytes the index (byte 2 and 3) and subindex (byte 4) of the code in which an error occurred are entered. Byte 5 to 8: In the data bytes 5 to 8 the error code is entered. The structure of the error code is reversed to the read direction. Example: The representation of the error code hex in the bytes 5 to 8 Read direction of the error code byte 6. byte 7. byte 8. byte Low word High word Low byte High byte Low byte High byte Possible error codes: Command 7th byte 8th byte Meaning 80 hex 6 6 Wrong index 80 hex 5 6 Wrong subindex 80 hex 3 6 Access denied 179

180 8 Configuration General information about the system bus (CAN) Parameter data transfer Examples of the parameter data telegram Read parameters The heatsink temperature C0061 (value: 43 C) is to be read out by the controller with the node address 5 via the parameter data channel 1. Identifier calculation Identifier of SDO 1 to the controller Calculation node address = 1541 Command "Read Request" (request to read controller parameter) Command Read request Index calculation Index Value 40 hex Calculation code number = = 5FC2 hex Telegram to drive: User data Command Index Index Subindex Data 1 Data 2 Data 3 Data 4 Identifier Low byte High byte hex C2 hex 5F hex Telegram from drive Identifier: SDO 1 from controller (= 1408) + node address = 1413 Command: "Read Response" response to read request with the actual value = 43 hex Index of read request: 5FC2 hex Subindex: 0 Data 1 to data 4: F B0 = 430, ,000 : 10,000 = 43 C User data Command Index Index Subindex Data 1 Data 2 Data 3 Data 4 Identifier Low byte High byte hex C2 hex 5F hex 00 B0 hex 8F hex 06 hex

181 Configuration General information about the system bus (CAN) Parameter data transfer 8 Write parameters The acceleration time C0012 (parameter set 1) of the controller with the node address 1 is to be changed via the SDO 1 (parameter data channel 1) to 20 seconds. Identifier calculation Identifier of SDO 1 to the controller Calculation node address = 1537 Command "Write Request" (transmit parameters to the drive) Command Write request Index calculation Index Value 23 hex Calculation code number = = 5FF3 hex Subindex: 0 Calculation of the acceleration time Data Value of acceleration time Telegram to drive Calculation 20 s 10,000 = 200,000 dec = D 40 hex User data Command Index Index Subindex Data 1 Data 2 Data 3 Data 4 Identifier Low byte High byte hex F3 hex 5F hex hex 0D hex 03 hex 00 Drive response to correct execution User data Command Index Index Subindex Data 1 Data 2 Data 3 Data 4 Identifier Low byte High byte hex F3 hex 5F hex Identifier SDO 1 from controller = node address = 1409 Command = "Write Response" (controller response (acknowledgement)) = 60 hex 181

182 8 Configuration General information about the system bus (CAN) Addressing of the parameter and process data objects Addressing of the parameter and process data objects The CAN bus system is based on a message oriented data exchange between a transmitter and many receivers. Thus, all nodes can transmit and receive messages at the same time. The identifier in the CAN telegram also called COB ID (Communication Object Identifier) controls which node is to receive a transmitted message. With the exception of the network management (NMT) and the sync telegram (Sync) the identifier contains the node address of the drive besides the basic identifier: Identifier (COB ID) = basic identifier + adjustable node address (node ID) The basic identifier is preset with the following values: Object to the drive Direction from the drive Basic identifier dec hex NMT 0 0 Sync PDO1 (Process data channel 1) PDO2 (Process data channel 2) PDO3 (Process data channel 3) RPDO1 TPDO1 RPDO1 TPDO1 RPDO1 TPDO1 XCAN1_IN CAN1_IN CANaux1_IN XCAN1_OUT CAN1_OUT CANaux1_OUT XCAN2_IN CAN2_IN CANaux2_IN XCAN2_OUT CAN2_OUT CANaux2_OUT XCAN3_IN CAN3_IN CANaux3_IN XCAN3_OUT CAN3_OUT CANaux3_OUT x x x x x x SDO1 x (Parameter data channel 1) x SDO2 x (Parameter data channel 2) x C0 Node guarding x Note! Chapter "8.2.1 Setting of CAN node address and baud rate" contains information on Setting of the node address ( 183). Selective addressing ( 186). Display of the resulting identifiers The display code for the resulting identifiers is for the MotionBus (CAN) C0355. System bus (CAN) C2455. Here you cannot predefine values. 182

183 Configuration Configuring MotionBus/system bus (CAN) Setting CAN node address and baud rate Configuring MotionBus/system bus (CAN) Note! ECSxM... axis modules only use the channels CAN1_IN and CAN1_OUT for communication via the MotionBus (CAN) interface X4. do not support process data via the system bus (CAN) interface X14, i.e. data cannot be processed using the channels CANaux_IN and CANaux_OUT Setting CAN node address and baud rate The node address and baud rate for the MotionBus (CAN) can be set via DIP switch or codes. The node address and baud rate for the system bus (CAN) must be set via codes only Settings via DIP switch Fig.8 11 DIP switch for node address and baud rate (all switches: OFF) ECS_COB

184 8 Configuration Configuring MotionBus/system bus (CAN) Setting CAN node address and baud rate Node address setting The node address is set via DIP switches These switches are assigned to certain valencies. The sum of valencies results in the node address to be set (see example). Example Switch Valency Switching status 1 Any 2 32 ON 3 16 ON 4 8 ON 5 4 OFF 6 2 OFF 7 1 OFF Node address = 56 Baud rate setting Note! The baud rate must be set identically for all controllers and the master computer. Switch Baud rate [kbit/s] ON OFF OFF OFF OFF 9 OFF OFF OFF ON ON 10 OFF OFF ON OFF ON 184

185 Configuration Configuring MotionBus/system bus (CAN) Setting CAN node address and baud rate Settings via codes Note! The codes C0350 (node address) and C0351 (baud rate) are inactive if one of the DIP switches is set to the "ON" position. In order that communication via the CAN bus can take place, the baud rate must be identical for all controllers and the master control. If the Lenze setting has been loaded via C0002, C0351 is set to 0 (500 KBit/s). The CAN baud rate and CAN node address must be reset. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0350 CAN address 1 Node address for CAN bus interface X4 C0351 CAN baud rate 0 {4} 1 {1} 63 Baud rate for CAN bus interface kbit/s X4 Note: When the Lenze setting is kbits/sec loaded via C0002, C0351 is set kbit/s to 0 (500 KBit/s) kbit/s kbit/s Save changes with C0003 = 1. The settings are only accepted after carrying out one of the following actions: Switching on of the low voltage supply Command Reset node" via the bus system Reset node via C0358 ( 188) 185

186 8 Configuration Configuring MotionBus/system bus (CAN) Setting CAN node address and baud rate Selective addressing Use C0354 to set the controller address independent of the node address in C0350. To make the alternative node address valid, set the corresponding subcode C0353/x = 1. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0353 Source for alternative bus node addresses of CAN_IN/CAN_OUT (CAN bus interface X4) C CAN addr sel 0 CAN node address (C0350) Address CAN1_IN/OUT 2 CAN addr sel 0 CAN node address (C0350) Address CAN2_IN/OUT 3 CAN addr sel 0 CAN node address (C0350) Address CAN3_IN/OUT 0 C0350 (auto) Automatically determined by C C0354 (man.) Determined by C0354 Alternative node addresses for CAN_IN/CAN_OUT (CAN bus interface X4) 1 CAN addr {1} 512 Address 2 CAN1_IN 2 CAN addr. 1 Address 2 CAN1_OUT 3 CAN addr. 257 Address 2 CAN2_IN 4 CAN addr. 258 Address 2 CAN2_OUT 5 CAN addr. 385 Address 2 CAN3_IN 6 CAN addr. 386 Address 2 CAN3_OUT Save changes with C0003 = 1. The settings are only accepted after carrying out one of the following actions: Switching on of the low voltage supply Command Reset node" via the bus system Reset node via C0358 ( 188) 186

187 Configuration Configuring MotionBus/system bus (CAN) Defining boot up master in the drive system Defining boot up master in the drive system If the bus initialisation and the related state change of "Pre Operational" to "Operational" is not executed by a higher level master system, the controller can be intended for the master to execute this task. The MotionBus (CAN) is configured via code C0352. The master functionality is only required for the initialisation phase of the drive system. In the initialisation phase, C0356 serves to set a boot up time for the master. ( 188). With the NMT telegram start_remote_node (broadcast telegram) the master sets all nodes in the NMT status "Operational". Data via the process data objects can only be exchanged during this status. Note! The change of the master/slave operation only becomes effective after a renewed mains switching of the controller or by sending one of the NMT telegrams reset_node or reset_communication to the controller. As an alternative to the NMT telegram reset_node the code C0358 ("Reset Node") is available for a reinitialisation of the CAN specific device parameters. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0352 CAN mst 0 Master/slave configuration for CAN bus interface X4 0 Slave CAN boot up is not active 1 Master CAN boot up is active 2 Master with node guarding 3 Slave and heartbeat producer 4 Slave with node guarding

188 8 Configuration Configuring MotionBus/system bus (CAN) Setting of boot up time/cycle time Setting of boot up time/cycle time Setting boot up time code Meaning C0356/1 Time (in ms) when the activation starts after the low voltage supply is switched on. Only valid if C0352 = 1 (master). Normally the Lenze setting (3000 ms) is sufficient. If several controllers are interconnected and there is no higher level host, one of the controllers must initialise the CAN network. The master activates the entire network once at a specific instant and thus starts the process data transfer. Status changes from "pre operational" to operational". Set the cycle time for output data: code Meaning C0356/2 Cycle time (in ms) CAN2_OUT Setting "0" = event controlled transmission (The output data will only be sent if a value changes in the output object. C0356/3 Cycle time (in ms) CAN3_OUT Setting "0" = event controlled transmission (The output data will only be sent if a value changes in the output object. C0356/4 Delay time (in ms) for sending telegrams via the process data object CAN2_OUT/CAN3_OUT When the Operational NMT status (after Pre Operational) has been reached, the CANdelay delay time is started. After the delay time has elapsed, the PDOs CAN2_OUT and CAN3_OUT is sent for the first time Executing a reset node The following changes only become valid after a reset node: Changes of the baud rates Changes of the addresses of process data objects Changes of the MotionBus node addresses. Reset node can be made by: Switching on the low voltage supply Reset node via the bus system Reset node via C0358 Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0358 Reset Node 0 Execute reset node (CAN bus) No function 1 CAN reset 188

189 Configuration Configuring MotionBus/system bus (CAN) CAN bus synchronisation CAN bus synchronisation By means of the system bus synchronisation, the internal time base can be synchronised with the instant of reception of the sync signal. By this, the start of cyclic and time controlled internal processes of all drives involved in the synchronisation is synchronous. Operating mode The operating mode (sync signal source) is set via C1120: Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C1120 Sync mode 0 Sync signal source {1} 0 OFF Off 1 CAN Sync Sync connection via CAN bus Terminal Sync Sync connection via terminal 194 Synchronisation time The synchronisation process requires an additional period of time after the mains connection and the initialisation phase. The synchronisation time depends on the baud rate of the CAN bus, the starting time (arrival of the first sync signal), the time interval between the sync signals, the sync correction factor (C0363), the operating mode (C1120). The synchronisation time can be set via the code C0369. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0369 SyNc Tx Time 0 {0} CAN sync transmission cycle for CAN bus interface X4 A sync telegram with the identifier set in C0368 is sent with the set cycle time. 0 {1 ms} = switched off

190 8 Configuration Configuring MotionBus/system bus (CAN) Axis synchronisation via CAN bus interface Axis synchronisation via CAN bus interface The CAN bus transmits the sync signal and the process signals. Application examples: Selection of cyclic, synchronised position setpoint information for multi axis applications via the CAN bus Synchronisation cycle For the purpose of synchronisation the master sends a periodic sync signal. The controllers receive the sync signal and compare the time between two LOW HIGH edges of the signal with the preselected cycle time (C1121). Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C1121 Sync cycle 2 Synchronisation cycle 190 CAN sync identifier 1 {1 ms} 13 Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0367 Sync Rx ID 128 CAN sync receipt ID for CAN bus interface X {1}

191 Configuration Configuring MotionBus/system bus (CAN) Axis synchronisation via CAN bus interface 8 Phase shift The synchronisation phase (C1122) defines the period of time of the offset by which the start of the controller internal cycle lags behind the sync signal received. Note! Always set the synchronisation phase greater than the maximum possible temporal jitter* of the sync signals received! * Jitters are phase shiftings and hence periodic changes of signal frequencies. They are shiftings of fixed instants of a digital signal (e.g. the transition instant from one signal amplitude to another). Jitters especially occur at high frequencies and may cause data losses. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C1122 Sync phase Synchronisation phase {0.001 ms} Correction value of phase controller The CAN sync correction increment (C0363) specifies the increment by means of which the rule cycle is extended or shortened (e. g. in order to shift the starting time). As a rule, the factory set smallest value can be maintained. Only in disadvantageous cases (e. g. if the sync master does not observe its cycle time precisely enough), it may be necessary to extend the CAN sync correction increment so that the value in C4264 becomes minimal. Otherwise, an extension has rather disdavantageous effects on the drive features. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0363 Sync correct. 1.0 CAN sync correction increment Change correction value until C4264 reaches the minimum s/ms s/ms s/ms s/ms s/ms C4264 CanSync_Dev 0 Deviation of the control program synchronisation Only display {1}

192 8 Configuration Configuring MotionBus/system bus (CAN) Axis synchronisation via CAN bus interface Monitoring of the synchronisation (time slot) Sync-window Sync-signal Fig.8 12 Sync cycle Sync cycle "Time slot" for the LOW HIGH edges of the sync signal ECSXA474 Note! A jitter (see note 191) up to 200 s on the LOW HIGH edges of the sync signal is permissible. The amount of the jitter has an impact on the parameterisation of the "time slot". C3165 can be used for monitoring the synchronisation. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C1123 Sync window 0,010 Synchronisation window If the sync telegram/signal sent by the master is inside this "time slot", C3165 is set to 1. C3165 SyncInsideWi n 0,000 {0.001 ms} 6,500 0 CAN synchronisation inside the window Only display 0 {1 bit} CAN sync response Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0366 Sync Response 1 CAN sync response for CAN bus interface X4 0 No response 1 Response 192 Note! In C0366 the value "1" must be set permanently. 192

193 Configuration Configuring MotionBus/system bus (CAN) Axis synchronisation via CAN bus interface 8 Setting sequence: Observe the following sequence in the commissioning phase: Device Step Description All devices 1. Commission the controller and the CAN bus. 2. Inhibit the controller. Press key <F9> in the GDC. 139 Slaves 3. Connect "CANSync InsideWindow" with digital output. 4. C1120 = 1 Active synchronisation by sync telegram via CAN bus. 5. C0366 = 1 (Lenze setting) CAN sync reaction: Slaves respond to sync telegram. Master 6. Define the telegram (identifier) sequence: A. Send new setpoint to all slaves. B Send sync telegram. C Receive response of all slaves. 7. Start communication/send sync telegrams. Slaves 8. Read C0362 of the master. Retrieve cycle time of the sync telegram from the master. 9. Set C1121 according to C0362 of the master. Adjust the time distance of the sync telegrams to be received to the cycle time of the master. 10. Set C1123. Set optimum size for the "time slot". If the sync signal "jitters" heavily ( 191), increase "time slot". Slaves 11. Enable the controller via the signal "CANSync InsideWindow" applied to the digital output. Monitoring of the synchronisation: If "CANSync InsideWindow" = TRUE, enable the controller. 193

194 8 Configuration Configuring MotionBus/system bus (CAN) Axis synchronisation via terminal Axis synchronisation via terminal The transmission paths for the sync signal and the process signals are separated. The process signals are connected via a freely selectable input channel (e.g. AIF interface, digital frequency input). The sync signal is injected via the digital input X6/DI2. Application examples: Entry of cyclic, synchronised position setpoint information for multi axis applications via other bus systems (e.g. INTERBUS). Synchronisation of the internal processing cycles to superimposed process controls. Observe the following sequence in the commissioning phase: Site Step Description All devices 1. Commission the controller and the CAN bus. 2. Inhibit the controller. Press key <F9> in the GDC. 139 Slaves 3. Connect "CANSync InsideWindow" with digital output. 4. Apply the sync signal of the master to terminal X4/CH. Slaves 5. C1120 = 2 Active synchronisation by sync signal via terminal X4/CH. Slaves 6. C0366 = 1 (Lenze setting) CAN sync reaction: Slaves respond to sync telegram. Master 7. Start communication/send sync signals. Slaves 8. Read C0362 of the master. Retrieve cycle time of the sync signal from the master. 9. Set C1121 according to C0362 of the master. Adjust the time distance of the sync signal to be received to the cycle time of the master. 10. Set C1123. Set optimum size for the "time slot". If the sync signal "jitters" heavily ( 191), increase "time slot". 11. Enable the controller via the signal "CANSync InsideWindow" applied to the digital output. Monitoring of the synchronisation: If "CANSync InsideWindow" = TRUE, enable the controller. 194

195 Configuration Configuring MotionBus/system bus (CAN) Diagnostic codes Diagnostic codes The operation via the MotionBus (CAN) can be observed via the following diagnostic codes: C0359: Bus state C0360: Telegram counter C0361: Bus load Bus status (C0359) C0359 shows the current operating state of the MotionBus (CAN). Value of Operating state Description C Operational The bus system is fully operational. 1 Pre Operational Only parameters (codes) can be transferred via the bus system. Data exchange between controllers is not possible. A change into the state operational" can be made via a special signal on the MotionBus (CAN). Changing from "pre operational" to "operational" can be carried out by the following actions: Master functionality of a higher level host system If a drive is determined as master via C0352, the operating state is automatically changed for the entire drive system after the set boot up time C0356 (subcode 1), when power is switched on. Reset node via C0358 ( 188) With a binary input signal Reset node", which can be set correspondingly. Reset node via connected host system 2 Warning Faulty telegrams have been received. The controller remains passive (does not send any data). Possible reasons: Missing bus termination Insufficient shielding Potential differences in the grounding of the control electronics Bus load is too high Controller is not connected to MotionBus (CAN) 3 Bus off Too many faulty telegrams. The controller is disconnected from the MotionBus (CAN). It can be reconnected by: TRIP reset Reset node ( 188) Renewed mains connection 195

196 8 Configuration Configuring MotionBus/system bus (CAN) Diagnostic codes Telegram counter (C0360) C0360 counts for all parameter channels those telegrams that are valid for the controller. The counters have a width of 16 bits. If a counter exceeds the value 65535, the counting process restarts with 0. Counted messages: C0360 Meaning Subcode 1 All sent telegrams Subcode 2 All received telegrams Subcode 3 Sent telegrams of CAN1_OUT Subcode 4 Telegrams sent from CAN2_OUT Always "0" since channel is not used! Subcode 5 Telegrams sent from CAN3_OUT Always "0" since channel is not used! Subcode 6 Telegrams sent from parameter data channel 1 Subcode 7 Telegrams sent from parameter data channel 2 Subcode 8 Telegrams received from CAN1_IN Subcode 9 Telegrams received from CAN2_IN Always "0" since channel is not used! Subcode 10 Telegrams received from CAN3_IN Always "0" since channel is not used! Subcode 11 Telegrams received from parameter data channel 1 Subcode 12 Telegrams received from parameter data channel 2 196

197 Configuration Configuring MotionBus/system bus (CAN) Diagnostic codes Bus load (C0361) It can be detected via C0361 which bus load in percent is needed by the controller or by the single data channels. Faulty telegrams are not considered. Bus load of the single subcodes: C0361 Meaning Subcode 1 All sent telegrams Subcode 2 All received telegrams Subcode 3 Sent telegrams of CAN1_OUT Subcode 4 Telegrams sent from CAN2_OUT Always "0" since channel is not used! Subcode 5 Telegrams sent from CAN3_OUT Always "0" since channel is not used! Subcode 6 Telegrams sent from parameter data channel 1 Subcode 7 Telegrams sent from parameter data channel 2 Subcode 8 Received telegrams of CAN1_IN Subcode 9 Telegrams received from CAN2_IN Always "0" since channel is not used! Subcode 10 Telegrams received from CAN3_IN Always "0" since channel is not used! Subcode 11 Telegrams received from parameter data channel 1 Subcode 12 Telegrams received from parameter data channel 2 The data transfer is limited. The limits are determined by the number of telegrams transferred per time unit and by the data transfer speed. The limits can be determined during data exchange in a drive network by adding all drives involved under code C0361/1. Example: Drives/host system Bus load C0361/1 controller % C0361/1 controller % Host system 16.0 % 52.1 % (total) Two drives and the master system are interconnected via the MotionBus (CAN). Note! Max. bus load of all devices involved: 80 % If other devices are connected, as for instance decentralised inputs and outputs, their telegrams must be taken into consideration. Bus overload can, for instance, be caused by sync telegrams sent with a too short time interval. Remedy: Change synchronisation cycle of higher level control and controller (C1121). 197

198 Monitoring functions (overview) Monitoring The responses ( 202) to monitoring functions partly can be parameterised via codes. Possible reactions Lenze setting Can be set Fault message Description Source Code TRIP Message Warning Fail QSP Off x071 CCR System fault Internal x091 EEr External monitoring (activated via DCTRL) FWM C0581 x191 HSF Internal error Internal Voltage supply 1020 OU Overvoltage in the DC bus (C0173) MCTRL 1030 LU Undervoltage in the DC bus(c0174) MCTRL 0070 U15 Undervoltage of internal 15 V voltage supply Internal 0107 H07 Internal fault (power section) Internal Communication x041 AP1 Internal fault (signal processor) Internal x061 CE0 Communication error on the automation interface (AIF) AIF C0126 x062 CE1 Communication error on the CAN1_IN process data input object CAN1_IN C0591 (monitoring time adjustable via C0357/1) x063 CE2 Communication error on the CAN2_IN process data input object CAN2_IN C0592 (monitoring time adjustable via C0357/2) x064 CE3 Communication error on the CAN3_IN process data input object CAN3_IN C0593 (monitoring time adjustable via C0357/3) x065 CE4 BUS OFF status of MotionBus (CAN) CAN C0595 (too many faulty telegrams) x066 CE5 Communication error of the Gateway function (C0370, C0371) via CAN C0603 MotionBus (CAN) x122 CE11 Communication error on the CANaux1_IN process data input object ( time CANaux1_IN C2481 monitoring adjustable via C2457/1) x123 CE12 Communication error on the CANaux2_IN process data input object ( time CANaux2_IN C2482 monitoring adjustable via C2457/2) x124 CE13 Communication error on the CANaux3_IN process data input object ( time CANaux3_IN C2483 monitoring adjustable via C2457/3) x125 CE14 BUS OFF status of system bus (CAN) (too many faulty telegrams) CANaux C2484 x: 0 = TRIP, 1 = message, 2 = warning, 3 = FAIL QSP 1) Adjustable in the DDS under Project Exceptional handling 2) For ECSxA... only Monitoring functions 8 Configuration

199 199 Monitoring Fault message Description x126 CE15 Communication error of the Gateway function (C0370, C0371) via system bus (CAN) x260 Err Node "Life Guarding Event": Guard The controller configured as CAN slave does not receive a "Node Guarding" telegram with the "Node Life Time" from the CAN master. Possible reactions Lenze setting Can be set Source Code TRIP Message Warning Fail QSP Off CANaux C2485 Node Guarding C0384 2) Temperatures / sensors 0050 OH Heatsink temperature > 90 C MCTRL 0051 OH1 Interior temperature > 90 C MCTRL x053 OH3 Motor temperature > 150 C MCTRL C0583 x054 OH4 Heatsink temperature > C0122 MCTRL C0582 x055 OH5 Interior temperature > C0124 MCTRL C0605 x057 OH7 Motor temperature > C0121 MCTRL C0584 x058 OH8 Motor temperature via inputs T1 and T2 is too high. MCTRL C0585 x086 Sd6 Thermal sensor error on the motor (X7 or X8) MCTRL C0594 x095 FAN1 Fan monitoring (only for built in units) X110 H10 Thermal sensor error on heatsink FWM C0588 x111 H11 Thermal sensor error in the interior of the device FWM C0588 Motor / feedback system 0011 OC1 Short circuit of motor cable MCTRL 0012 OC2 Motor cable earth fault MCTRL 0015 OC5 I x t overload TRIP (axis module, fix 100 %) MCTRL 0016 OC6 I 2 x t overload TRIP (motor, C0120) MCTRL x017 OC7 I x t overload warning (axis module, C0123) MCTRL C0604 x018 OC8 I 2 x t overload warning (motor, C0127) MCTRL C0606 x032 LP1 Motor phase failure MCTRL C0599 Note: Can only be used for asynchronous motors. By activation of the motor phase failure detection, the calculating time provided to the user is minimised! x081 Rel1 Open circuit monitoring of the brake relay output (X25) FWM C0602 x082 Sd2 Resolver error at X7 MCTRL C0586 Note: If monitoring is switched off or in the case of "Warning", the machine can reach very high speeds in the case of fault, which may result in the damage of the motor and the machine that is driven! x085 Sd5 Master current value encoder error on analog input X6/AI+, AI (C0034 = 1) MCTRL C0598 x: 0 = TRIP, 1 = message, 2 = warning, 3 = FAIL QSP 1) Adjustable in the DDS under Project Exceptional handling 2) For ECSxA... only Monitoring functions Configuration 8

200 200 Monitoring Possible reactions Lenze setting Can be set Fault message Description Source Code TRIP Message Warning Fail QSP Off x087 Sd7 Absolute value encoder error at X8 MCTRL x088 Sd8 SinCos encoder error on X8 MCTRL C0580 x089 PL Error with regard to rotor position adjustment MCTRL Speed x190 nerr Speed control error (monitoring window C0576) MCTRL C0579 x200 Nmax Maximum speed (C0596) has been exceeded. MCTRL C0607 Float error 0209 float Sys T Float error in system task (ID 0) Internal 1) 0210 float Cycl. T Float error in cyclic task (PLC_PRG ID 1) Internal 1) 0211 float Task1 Float error in task 1 (ID 2) Internal 1) float Task8 Float error in task 8 (ID 9) Time out / overflow 0105 H05 Internal fault (memory) Internal x108 H08 Extension board not connected properly or not supported by program. Internal 0201 overrun Time out in task 1 (ID 2) Internal 1) Task overrun Time out in task 8 (ID 9) Task overrun Time out in cyclic task (PLC_PRG, ID 1) Internal Cycl. T 0220 not Fkt Not enough technology units available in the PLC. Internal Credit 0230 No program No PLC program loaded in the PLC. Internal 0231 Unallowed You have called the library function in the PLC program. This function is not Internal Lib supported. x240 ovrtrans Overflow of the transmit request memory Free CAN Queue objects x241 ovr Receive Too many receive telegrams Free CAN objects x: 0 = TRIP, 1 = message, 2 = warning, 3 = FAIL QSP 1) Adjustable in the DDS under Project Exceptional handling 2) For ECSxA... only Monitoring functions 8 Configuration

201 201 Monitoring Possible reactions Lenze setting Can be set Fault message Parameter setting Description Source Code TRIP Message Warning Fail QSP Off 0072 PR1 Check sum error in parameter set 1 Internal 0074 PEr Program error Internal 0075 PR0 Error in the parameter sets Internal 0079 PI Error during parameter initialisation Internal 0080 PR6 For ECSxS/P/M:Internal fault Internal For ECSxA: Too many user codes Application specific fault messages x400 Pos HW End Positive hardware limit switch has bee approached. C3175 x401 Neg HW Negative hardware limit switch has been approached. C3175 End x404 Follow Err 1 Warning against exceeding the following error limit (C3030). C3032 x405 Follow Err 2 Following error limit (C3031) has been exceeded. C3033 x406 Home Pos Home position is unknown. C3170 Err x407 Toggle Bit Toggle bit error C3160 Err 3408 External Externally enabled quick stop (QSP) via X6/DI1 QSP (A reset of the fault message is required.) x410 VelModeErr Speed error in "Velocity Mode" (C5000 = 2) C3038 x: 0 = TRIP, 1 = message, 2 = warning, 3 = FAIL QSP 1) Adjustable in the DDS under Project Exceptional handling 2) For ECSxA... only Monitoring functions Configuration 8

202 8 Configuration Configuring monitoring functions Reactions 8.4 Configuring monitoring functions Reactions Different monitoring functions ( 198) protect the drive system from impermissible operating conditions. If a monitoring function is activated, the corresponding response for device protection is initiated. the fault message is entered in position 1 in the history buffer ( 226). In the history buffer (C0168/x), the fault messages are saved with an offset indicating the type of reaction: Fault message number 0xxx 1xxx 2xxx 3xxx Type of reaction TRIP Message Warning FAIL QSP Example: C0168/1 = 2061 x061: The current fault (subcode 1 of C0168) is a communication error (fault message "CE0"/No. "x061") between the AIF module and the ECS axis module. 2xxx: The reaction to this is a warning. 202

203 Configuration Configuring monitoring functions Reactions 8 Effects of responses Response Impact Display Operating unit RDY IMP Fail TRIP Message TRIP active: The power outputs U, V, W are switched to high resistance. The drive is idling (no control!). TRIP reset: The drive runs to its setpoint within the deceleration times set. Danger! The drive restarts automatically if the message is removed! Message active: The power outputs U, V, W are switched to high resistance. FAIL QSP Warning Off 0.5 s The drive is idling (no control!). > 0.5 s The drive is idling (due to internal controller inhibit!). If required, restart program. Message reset: The drive runs to its setpoint with the maximum torque. The drive is braked to standstill within the quick stop time (C0105). Stop! The drive can be destroyed as a result of deactivated monitoring functions! The failure merely is displayed, the drive runs on in a controlled manner. Stop! The drive can be destroyed as a result of deactivated monitoring functions! No response to the failure is effected! = off = on 203

204 8 Configuration Configuring monitoring functions Monitoring times for process data input objects Monitoring times for process data input objects Each process data input object can monitor whether a telegram has been received within a specified time. As soon as a telegram arrives, the corresponding monitoring time (C0357/C02457) is restarted ("retriggerable monoflop" function). The following assignments are valid: Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0357 Monitoring time for CAN1...3_IN (CAN bus interface X4) C CE monit time {1 ms} CE1 monitoring time 2 CE monit time 3000 CE2 monitoring time 3 CE monit time 3000 CE3 monitoring time Monitoring time for CANaux1...3_IN (CAN bus interface X14) 1 CE monit time {1 ms} CE11 monitoring time 2 CE monit time 3000 CE12 monitoring time 3 CE monit time 3000 CE13 monitoring time The following responses can be set for communication errors: 0 = Fault (TRIP) controller sets controller inhibit (CINH) 2 = Warning 3 = Monitoring is switched off Codes for setting the response to the monitoring: CAN bus interface Code Monitoring C0591 CAN1_IN ("CE1") C0592 CAN2_IN ("CE2") X4 ECSxS/P/M: MotionBus (CAN) C0593 CAN3_IN ("CE3") ECSxA: system bus (CAN) C0595 Bus Off ("CE4") C0603 Gateway function ("CE5") C2481 CANaux1_IN ("CE11") C2482 CANaux2_IN ("CE12") X14 C2483 CANaux3_IN ("CE13") System bus (CAN) C2484 Bus Off ("CE14") C2485 Gateway function ("CE15") The input signals (CAN1...3_IN/CANaux1...3_IN) can also be used as binary output signals, e. g. for the assignment of the output terminal. Bus off If the controller separates from the MotionBus/system bus (CAN) due to faulty telegrams, the "BusOffState" signal (CE4/CE14) is set. "BusOffState" can trip an error (TRIP) or warning. It is also possible to switch off the signal. The response can be set via C0595/C2484. For this, the terminal output can be assigned, too. 204

205 Configuration Configuring monitoring functions Motor temperature (OH3, OH7) 8 Reset node Changes with regard to baud rates, CAN node addresses, or addresses of process data objects only are valid after a reset node. A node can be reset by: Switching on the low voltage supply again Reset node via the bus system Reset node via C0358/C2458 ( 188) Motor temperature (OH3, OH7) The motor temperature is monitored by means of a continuous thermal sensor (KTY). Wire the thermal sensor to the resolver cable on X7 ( 74) or to the encoder cable on X8 ( 75). Adjustable warning threshold (OH7) via C0121 Fixed threshold (OH3) = 150 C The reaction to exceeding the thresholds can be defined via: C0584 (adjustable threshold) C0583 (fixed threshold) Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0121 OH7 limit 120 Adjustable threshold for early motor temperature warning 45 {1 C} 150 Motor temperature > C0121 fault OH7 C0583 MONIT OH3 0 Configuration of motor temperature monitoring via resolver input X7 or encoder input X8 0 TRIP 2 Warning 3 Off C0584 MONIT OH7 2 Configuration of motor temperature monitoring via resolver input X7 or encoder input X8 Set threshold in C TRIP 2 Warning 3 Off

206 8 Configuration Configuring monitoring functions Heatsink temperature (OH, OH4) Heatsink temperature (OH, OH4) The heatsink temperature of the controller can be monitored with a temperature threshold: Adjustable threshold (OH4) via C0122 Fixed threshold (OH) = 90 C The reaction to exceeding the adjustable threshold can be defined via C0582. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0122 OH4 limit 80 Adjustable threshold for early heatsink temperature warning 45 {1 C} 90 Heatsink temperature > C0122 fault OH4 C0582 MONIT OH4 2 Configuration of heatsink temperature monitoring Set threshold in C TRIP 2 Warning 3 Off

207 Configuration Configuring monitoring functions Interior temperature (OH1, OH5) Interior temperature (OH1, OH5) The temperature inside the device is permanently monitored with two temperature thresholds: Adjustable threshold (OH5) via C0124 Fixed threshold (OH1) = 90 C The reaction to exceeding the adjustable threshold can be defined via C0605. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0124 OH5 limit 75 Adjustable threshold for early warning of temperature inside the device 10 {1 %} 90 C0062 C0124 fault OH5 C0605 MONIT OH5 2 Configuration of early warning of temperature inside the device (threshold in C0124) 0 TRIP 2 Warning 3 Off Function monitoring of the thermal sensors (H10, H11) The function of the thermal sensors of heatsink and the interior of the device. If the thermal sensors report values beyond the measuring range, the fault H10 (heatsink) or H11 (interior) is reported. The response to the faults can be defined via C0588. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0588 MONIT H10/H11 0 Configuration of monitoring Thermal sensors (H10, H11) in the controller "SensFaultTht/SensFaultTid" (FWM H10/H11) 0 TRIP 2 Warning 3 Off

208 8 Configuration Configuring monitoring functions Controller current load (I x t monitoring: OC5, OC7) Controller current load (I x t monitoring: OC5, OC7) The I x t monitoring monitors the current load of the axis module. The monitoring is set in a way that operation is permanently enabled with a device output current = I N. is possible for 30 s with a device output current 1.5 x I N. The overload protection of the axis module can be set with thresholds: adjustable threshold (OC7) via C0123 fixed threshold (OC5) = 100 % After an overcurrent phase you can calculate with a recovery phase of 120 s. For a more precise consideration consult the overcurrent characteristic and the value 3 x axis module ( 209). The response for the excess of the adjustable threshold is defined via C0604. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0123 OC7 limit 90 Adjustable threshold for I x t advance warning (axis module) 0 {1 %} 100 C0064 C0123 fault OC7 C0604 MONIT OC7 2 Configuration of early warning I x t threshold (C0123) 0 TRIP 2 Warning 3 Off

209 Configuration Configuring monitoring functions Controller current load (I x t monitoring: OC5, OC7) 8 Overcurrent characteristic t TRIP [s] ECSxS/P/M/A064 ECSxS/P/M/A048 ECSxS/P/M/A004, -008, -016, I/I r Fig.8 13 Overcurrent characteristic ECSxM..., see also Rated data 25 ECSXA025 The overcurrent characteristic shows the maximum time t TRIP till the axis module generates an I x t error. In order to reach this time t TRIP again, the time 3 x axis module with the load I/I r = 0 A must be observed. Device axis module [s] Overcurrent characteristic ECSxM ECSxM ECSxM ECSxM ECSxM ECSxM I t I subprofile_x I rated I subprofile_x I t I subprofile_x1 rated t subprofile_x e axis_module 209

210 8 Configuration Configuring monitoring functions Motor current load (I 2 x t monitoring: OC6, OC8) Motor current load (I 2 x t monitoring: OC6, OC8) The I 2 x t load of the motor is continually calculated by the axis module and is displayed in C0066. Via C0120 and C0127 you can set two actuation thresholds. If threshold 1 is exceeded, the response set in C0606 (OC8) is activated. If threshold 2 is exceeded, OC6 TRIP is activated. The I 2 x t monitoring is designed in a way that it is activated after 179 s for a motor current of 1.5 x I r and a set threshold of 100 % (thermal motor time constant C0128 = 5 min). Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0120 OC6 limit 105 Threshold for I 2 x t disconnection (motor) 0 {1 %} = I 2 x t monitoring is switched off I 2 x t > C0120 TRIP 006 C0127 OC8 limit 100 Threshold for I 2 x t advance warning (motor) 0 {1 %} 120 I 2 x t > C0127 response as set in C0606 C0128 Tau motor 5.0 Thermal time constant of the motor 1.0 {0.1 min} 25.0 For calculating the I 2 xt disconnection C0606 MONIT OC8 2 Configuration of I 2 x t early warning (threshold in C0120) 0 TRIP 2 Warning 3 Off

211 Configuration Configuring monitoring functions DC bus voltage (OU, LU) 8 Calculation of the release time: t (C0128) ln 1 y 1 I M I r I M I r y Current motor current Rated motor current C0120 or C0127 The release time for different motor currents and thresholds can be taken from the diagram (C0128 = 5.0 min): 2 I t [%] I mot =3xIr I mot =2xIr I mot =1.5xIr I mot = I r t[s] ECSXA040 Fig.8 14 I 2 x t monitoring: Release times with different motor currents Imot Motor current I r Rated motor current I 2 t I 2 t load T Time DC bus voltage (OU, LU) If the DC bus voltage exceeds the upper switch off threshold set in C0173, an OU message is actuated. If the DC bus voltage falls below the lower switch off threshold set in C0174, an LU message is actuated. Note! All drive components in DC bus connections must have the same thresholds! Selection Mains voltage Brake unit LU message (Undervoltage) C0173 Power supply module [V AC] Setting [V DC] Resetting [V DC] OU message (Overvoltage) Setting [V DC] Resetting [V DC] yes/no yes/no yes/no no yes yes/no C0174 C V (Lenze setting) yes/no C0174 C V yes/no C0174 C V no C0174 C V yes C0174 C V

212 8 Configuration Configuring monitoring functions Voltage supply of the control electronics (U15) Voltage supply of the control electronics (U15) If the voltage at X6/DI1 or X6/DI3 falls below 17 V, TRIP "U15" is actuated. The fault can only be reset if U > 19 V Motor phases (LP1) This monitoring function checks whether a motor phase has failed. Note! This monitoring function can only be used for asynchronous motors. When this monitoring function is activated, the calculating time provided to the user is reduced. The response is set via C0597. The monitoring limit is set via C0599. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0597 MONIT LP1 3 Configuration of motor phase monitoring (LP1) When this monitoring function is activated, the calculating time which is provided to the user is reduced! TRIP 2 Warning 3 Off C0599 Limit LP1 5.0 Monitoring limit for motor phase monitoring (LP1) referred to the current limit. 0,01 {0.01 %}

213 Configuration Configuring monitoring functions Resolver supply cable (Sd2) Resolver supply cable (Sd2) This monitoring function monitors the resolver feed cable and the resolver with regard to open circuit and protects the motor. Stop! If monitoring is disconnected, the machine can achieve very high speeds in case of faults (e. g. system cable is disconnected or not correctly screwed), which can result in the damage of the motor and of the driven machine! The same applies if "warning" is set as a response. For commissioning C0586, always use the Lenze setting (TRIP). Only use the possibility of disconnection via C0586 if the monitoring is activated without apparent reason (e. g. by very long cables or intense interference injection of other drives). If a fault with regard to the survey of the actual speed value is available, it is not definitely ensured that monitoring is activated with regard to overspeed (NMAX, 216). This monitoring... is automatically activated if a resolver is selected as an actual speed value encoder via C0419. is automatically activated if another actual speed value encoder is selected. The response is set via C0586. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0586 MONIT SD2 0 Configuration of monitoring Resolver "ResolverFault" (MCTRL Sd2) 0 TRIP 2 Warning 3 Off Motor temperature sensor (Sd6) This monitoring function checks whether the motor temperature sensor provides values within the measuring range of C. If the values are beyond this measuring range, monitoring is activated. The response is set via C0594. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0594 MONIT SD6 3 Configuration of monitoring Motor temperature sensor " SensorFault" (MCTRL Sd6) 0 TRIP 2 Warning 3 Off

214 8 Configuration Configuring monitoring functions SinCos encoder (Sd8) SinCos encoder (Sd8) This monitoring function identifies via a plausibility check whether the encoder is available and the sin/cos tracks supply plausible values with regard to each other. The following SinCos encoder types are supported: Stegmann SCS 60/70 ST 512 single turn absolute value encoder (512 incr./rev.). Stegmann SCM 60/70 ST 512 multi turn absolute value encoder (512 incr./rev.). The fault "Sd8" can only be reset by mains switching. If required, the encoder has to move by several angular degrees for actuating a fault. The response is set via C0580. The filter time constant (C0559) serves to filter short time trouble on the sin/cos track of the encoder without an SD8 trip being released immediately. Note! For the desired encoder monitoring, and in particular when using synchronous machines, set fault handling to "TRIP". In order to attain further encoder safety, additionally configure the following error monitoring ( 140). Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0580 Monit SD8 3 Configuration of open circuit monitoring for sin/cos encoders 0 TRIP 3 Off C0559 SD8 filter t 1 Filter time constant (SD8) 1 {1 ms} 200 Example: If the setting is "10 ms", a SD8 TRIP is actuated after 10 ms. 214 Visible faults Unplugged plug, all encoder signals open. Singe wire breakage, one of the following signals is missing: COS A RefCOS A SIN B RefSIN B GND VCC Double wire breakage with the following signal pairs: COS A and RefCOS A SIN B and RefSIN B COS A and SIN B RefCOS A and RefSIN B and all four signals (COS A, RefCOS A, SIN B, RefSIN B) open. Non visible faults Short circuits, in particular between sine and cosine signals. Cable/encoder faults with intermediate values "Semi" short circuits (> 0 Ohm) "Semi" interruptions (< infinite) 214

215 Configuration Configuring monitoring functions Speed beyond the tolerance margin (nerr) Speed beyond the tolerance margin (nerr) This monitoring function compares the actual speed value supplied by the tacho generator to the speed setpoint on the speed controller. If the difference of the two speed values exceeds the tolerance window set in C0576, the monitoring function is actuated. The subsequent speed behaviour of the drive controller can be evaluated by means of this monitoring. If the system deviation exceeds a certain value, this may indicate a drive problem. In this case, the drive somehow is inhibited from following the set speed setpoint. With regard to a generally functional drive controller, this may be caused by mechanical blockades on the load side, or by a motor torque that is not sufficient. Furthermore, a tacho generator in speed controlled operation can be protected further on by this monitoring. Thus, the monitoring presents a supplementation to the individual encoder monitoring systems. Faults on the encoder system bring about an incorrect actual speed value. This normally results in a system deviation on the speed controller that is greater than that in the normal operating status. The tolerance margin is set via C0576. The response is set via C0579. Note! Where required, adjust the setpoint ramps and/or the quick stop deceleration time by longer times to the application, so that no fault messages are output. Set the tolerance window (C0576) to at least twice the value of the system deviation occurring during operation. The value can be identified by respective tests when commissioning is effected. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0576 nerr Window 100 Monitoring window of the speed control error referring to n max. 100 % = lowest monitoring sensitivity 0 {1 %} 100 C0579 Monit nerr 3 Configuration of speed control error monitoring 0 TRIP 1 Message 2 Warning 3 Off 4 FAIL QSP

216 8 Configuration Configuring monitoring functions Maximum speed exceeded (NMAX) Maximum speed exceeded (NMAX) The monitoring process is activated when the current speed exceeds the upper speed limit of the system or the double value of C0011 (n max ). Stop! With regard to active loads (e. g. hoists), pay attention to the fact that the drive in this case operates without torque. Specific on site measures are required! If the actual speed value encoder fails, it is not provided that this monitoring will be activated. The upper speed limit of the system (maximum speed) is set via C0596. Code Possible settings IMPORTANT No. Designation Lenze/ {Appl.} Selection C0596 NMAX limit 5500 Monitoring: Maximum speed of the machine 0 {1 rpm}

217 Diagnostics Diagnostics with Global Drive Control (GDC) 9 9 Diagnostics 9.1 Diagnostics with Global Drive Control (GDC) In order to diagnose the current controller operation, click on Diagnostics Actual info in the GDC parameter menu. The table which appears then shows the current motor data, operating times, fault messages, etc. Fig.9 1 GDC view: Diagnostic of the current operation ECSXA546 The most important operating values are displayed in the parameter menu of the GDC under Diagnostic Display Motion: Fig.9 2 GDC view: Diagnostic of Display Motion The GDC parameter menu shows fault history values under Diagnostics History: ECSXA547 Fig.9 3 GDC view: Diagnostic history ECSXA

218 9 Diagnostics Diagnostics with Global Drive Oscilloscope (GDO) 9.2 Diagnostics with Global Drive Oscilloscope (GDO) The Global Drive Oscilloscope (GDO) is included in the scope of supply of the Lenze parameter setting and operating program "Global Drive Control (GDC)" and can be used as an additional diagnostics program. The GDO serves to e. g. record input and output data and device internal states during the controller operation. Note! Detailed information about the functionality and handling of GDO can be found in the Manual "Global Drive Oscilloscope (GDO), Getting started". Fig.9 4 Global Drive Oscilloscope (GDO) ECSXA480 Menu bar Symbol bar at the top Data sets Symbol bar on the left Graph display field Vertical operating elements Status display Trigger/cursor operating elements Horizontal operating elements Operating elements for recording 218

219 Diagnostics Diagnostics with Global Drive Oscilloscope (GDO) GDO buttons GDO buttons Clicking on the corresponding button executes the respective function. Press the <F1> key to call the HTML online help. Symbol bar at the top (, Fig.9 4) Symbol (button) Function Connect device Here a connection can be established to an attached module. This button has the same function as the menu command File Connect. Load offline set Here saved data sets can be loaded. Save set Here recorded curves can be saved. This button has the same function as the menu command File Save. Print set Here the recorded curve can be printed in different variants. Copy data Here data sets can be copied. This button has the same function as the menu command Edit Copy. Symbol bar on the left (, Fig.9 4) Symbol (button) Function Zoom Here different zoom functions can be executed. Automatic scaling Here all selected curves can be automatically scaled and repositioned and the offset value can be set to "0". The following data types are supported in automatic scaling: BYTE; WORD; DWORD; USINT; UINT; UDINT; SINT; INT; SDINT; Array; Struct Comment Here information concerning the current data set can be entered. This information is saved together with the current data set and after loading it is displayed as a short info. Delete Here the selected offline data set can be deleted. 219

220 9 Diagnostics Diagnostics with Global Drive Oscilloscope (GDO) Diagnostics with GDO Diagnostics with GDO 1. Connect axis module to the PC/laptop. Connection to terminal X14 (system bus (CAN)) with a PC system bus adapter. 2. Supply the axis module with a control voltage of 24 V ( 55). 3. Start the GDO on the PC/Laptop. 4. Click on the [ Connect device ] button. The dialog "Select Device" opens (Fig.9 5). The devices connected to the bus are listed under "Online". Fig.9 5 GDO view: Dialog "Select Device" 5. Select the corresponding device under "Online" and click on the [ OK ] button. The dialog "Select Drive PLC Developer Studio project symbol file" opens: ECSXA561 Fig.9 6 GDO view: Dialog "Select Drive PLC Developer Studio project symbol file" 6. Select symbol file ECSMot_Axxx.SDB (xxx = version number) and click on the [ OK ] button. ECSXA

221 Diagnostics Diagnostics with Global Drive Oscilloscope (GDO) Diagnostics with GDO 9 7. Select the variables the values of which are to be recorded during positioning. Double click on the yellow text box "Variable" in the group box "Vertical". Select the variables in the dialog box appearing now. The values of up to 8 variables can be displayed in the graph box. Fig.9 7 GDO view: Variable selection 8. Click on the [ START ] button to perform a positioning process. ECSXA563 Fig.9 8 GDO view: Performing a positioning process ECSXA564 System variables The meaning of the most important variables is shown in the following table: Variable Data type Signal type Code Display format Description Brake.L_BRK1.bSet_b Bool Binary Demands on brake logic Brake.L_BRK1.bOut_b Bool Binary Set brake CAN1_wDctrlCtrl Control word ( 104) Word CAN1_wDctrlStat Status word ( 106) CAN1_dnInD1_p CAN1_dnOutD1_p Double integer Double integer Position Position CAN1_bSyncInsideWindow_b Bool Binary C3165 bin CAN1_nSyncDeviation Integer Analog C4264 Set position [inc] inc = 1 revolution Actual position [inc] inc = 1 revolution Synchronisation telegram within the set window ( 192) Deviation of the control program synchronisation 221